Assembly & Testing Capabilities

State-of-the-Art Assembly and Test Services Facility

Our vertically integrated assembly and testing operations ensure these procedures are streamlined to deliver the highest-quality, qualified control systems on-time. Our ability to design and develop customized aerospace testing equipment to meet stringent requirements in extreme environments enables us to deliver the highest performing solutions to our customers.

Marotta Controls provides fully integrated naval, space, defense, and aerospace assembly and testing services designed to support mission-critical hardware from initial build through final qualification. Our in-house capabilities combine precision assembly, clean room manufacturing, and rigorous verification testing to ensure every active control product meets strict performance, safety, and environmental requirements. By performing assembly, functional validation, and acceptance testing under one roof, we help reduce program risk, shorten development timelines, and deliver compliant systems ready for deployment in extreme operating conditions.

The majority of components/systems produced by Marotta Controls are “active control products” requiring 100% final acceptance testing. To achieve this requirement, Marotta Controls maintains complete on-site, high-performance materials testing capabilities.

Pneumatic Testing

  • 40 pneumatic test benches
  • 33 pneumatic test benches @ 6,000 psi 
  • 11 pneumatic test benches @ 15,000 psi 
  • Flow rates of 150 SCFM
  • Grouped testing for up to 25,000 psi throughput

High Flow Testing

  • Gaseous nitrogen high-flow capability
  • 2 piping systems up to 7,500 psi
  • Up to 35,000 SCFM flow rate
  • High compressor capacity and large nitrogen storage

Special Fluids

  • Ammonia
  • Freon
  • Helium
  • Hydraulic Oil
  • Hydrogen
  • Hydrogen Peroxide
  • Inert Gas
  • Isopropyl Alcohol
  • Krypton
  • LNG
  • Nitrogen
  • Oxygen
  • RP-1
  • Skydrol
  • TEA-TEB
  • Xenon

Clean Room

  • 1,000 ft² Class 10,000/ISO 7 clean room on-site
  • FED-STD-209
  • 8 Flow Benches (Class 100) with flow hoods
  • Nonvolatile Residue Analysis:
    • Grade A Isopropyl alcohol filtered through 0.3-micron membrane, readable down to 0.01 mg
    • DC-190 high-temperature total organic carbon analyzer used with deionized water filtered through 0.2-micron membrane, readable to parts per million

Vibration Testing

  • Air-cooled electrodynamic shaker system
  • Up to 4,000 lbs. of force (lbf)
  • Velocities up to 70 inches per second (ips)
  • Payloads up to 1,000 lbs.
  • Electromechanical actuation and power systems testing

Thermal Altitude Testing

  • Altitude simulation up to 120,000 ft
  • Therrnal testing from -100ºF to 400ºF
  • 15 thermal chambers on-site to perform tests simultaneously
  •  Vacuum testing services to simulate up to 10-7 TORR

Acoustic Testing

  • 1,600 ft² acoustic testing facility
  • Structureborne & airborne noise testing
  • Dual acoustic chambers for low- and high-pressure testing
  • Test to less than 40 decibels for frequencies of 8 to 16,000 Hz
  • Blowdown through 2″ & 4″ lines directly from tank to atmosphere
  • Flow rate up to 270,000 SCFM at 6,300 psig

Hydraulic Testing

  • 4 high-pressure, high-flow hydraulic test units on-site
  • Flow rates of 25 GPM at 5,000 psig (MIL-H-83282 & 5606)
  • Short duration pressures up to 10,000 psig of CTFE (MIL-H6083 or 5606 hydraulic fluid)
  • Flow rates of 30 GPM at 6,000 psi Skydrol LD-4
  • Flow rates of 30 GPM at 1,500 psi of Lub Oil (MIL-PRF-23699)

Hydrostatic Testing

  • Fluids testing up to 60,000 psi
  • Gaseous Nitrogen or helium testing up to 25,000 psi
  • Walk-in proof chamber permits full operational control and visual assessment through bullet-proof glass viewing window

Welding

  • Laser, electron beam & gas tungsten arc welding (GTAW) beam
  • Certified nondestructive level 3 inspectors

Soldering

  • Soldering in accordance with IPC-J-STD-001
  • Space hardware soldered to IPC-A-610 & NASA STD-8739.3 

Lapping

  • In-house capability to achieve ± 1 µ
  • Flatness to ± 0.000001″