Supply and Return Headers
Welded or machined headers distribute coolant to drawing-defined rack branches while preserving port pitch and service access.
Direct Liquid Cooling Distribution Data Center Rack
Data Center Rack
Cooling Manifolds
Built Around Rack Interfaces
Build-to-print rack manifolds, branch headers, mounting brackets and connection kits for direct liquid cooling deployments. DRAmetal controls the released mechanical assembly from port geometry through leak-test records; the cooling system designer owns flow, pressure and thermal validation.
✓ Build-to-print scope
✓ Inspection by RFQ
✓ OEM approval boundary
RFQ Project-defined
RFQ
Example order size
Drawing
Critical dimensions
Plan
Inspection scope
OEM
Final approval
01 / What We Fabricate
Rack-Level Distribution Hardware Between the CDU and IT Equipment
These assemblies divide supply and return flow at the rack or row interface. The product boundary covers fabricated headers, ports, supports and released connection hardware rather than the complete CDU, controls or facility loop.
Rack Mounting Hardware
Brackets, rails and guards locate the manifold against cabinet datums without obstructing cables, doors or service paths.
Connection Kits
Released couplings, caps, drain points and identification hardware can be grouped by rack model and deployment revision.
Inspection Records
Port position, weld condition, cleanliness and drawing-defined pressure or leak tests are recorded against the assembly identity.
Our scope: released rack manifold hardware
DRAmetal manufactures the released mechanical assembly. The cooling system designer owns fluid compatibility, flow balance, pressure limits, thermal capacity, controls, field flushing and final system validation.
02 / Rack Manifold Types
Headers, Branch Modules and Installation Kits
Configuration starts with the rack layout, coolant architecture and service envelope supplied by the OEM or cooling integrator.
Rack Level Vertical Rack Distribution Manifolds
Supply and return headers mounted along the rear or side of a server rack.
- Layout Vertical paired headers
- CTQ Port pitch and orientation
- Mount Rack-specific brackets
CDU Branch CDU Branch Manifolds
Compact branch assemblies connecting a CDU outlet to multiple rack or row circuits.
- Scope Header and branch ports
- Control Flow-path cleanliness
- Record Specified leak test
Service Quick-Connect Interface Modules
Bracketed connection panels that position released couplings for repeatable hose access.
- Interface Drawing-defined couplings
- CTQ Centerline and clearance
- Protection Guards and caps
Deployment Rack Manifold Installation Kits
Manifold, brackets, guards and hardware grouped for a specific cabinet and site revision.
- Packout Rack and row identified
- Hardware BOM verified
- Trace Assembly serial or lot
03 / Technical Capabilities
Typical Rack Manifold Manufacturing Scope
| Materials | 304/316L stainless steel, aluminum and copper alloys to released drawings and fluid-compatibility requirements |
|---|---|
| Processes | Tube and header preparation, CNC machining, TIG welding or brazing, bracket fabrication, cleaning, assembly and drawing-defined leak testing |
| Critical interfaces | Port pitch, thread or coupling interface, bracket datum, hose clearance, drain orientation and rack service envelope |
| Quality records | Material identity, weld traveler, dimensional report, cleanliness record and pressure or leak-test result as specified |
| Packout | Protective caps, released fittings, brackets and fasteners grouped by rack, row, site and revision |
| Supply boundary | Fabricated rack distribution assembly; the system owner validates coolant chemistry, flow, pressure, thermal performance, controls and installation |
04 / Manufacturing Process
From Cooling Architecture to Leak-Tested Rack Kits
01
System Boundary Review
Confirm rack, CDU and facility responsibilities plus fluid, pressure and cleanliness requirements.
02
Port and Datum Mapping
Map every branch centerline, bracket datum, hose route and service clearance.
03
DFM and Test Plan
Review joints, tooling access, distortion risk, cleaning and the released test method.
04
Fabrication
Prepare headers, ports and brackets with material and revision identity maintained.
05
Assembly and Testing
Join, clean and test the assembly to the drawing-defined pressure, medium and acceptance criteria.
06
Fit and Packout
Verify rack interfaces and group protected components by deployment kit.
05 / Why It Matters
Why Rack Manifolds Need Interface-Level Control
A pressure-tight header can still fail installation if port pitch, hose clearance or bracket location is wrong.
Port Accumulation
Small centerline errors accumulate across multiple branches and load hoses or quick connects.
Weld Distortion
Joining sequence and fixturing protect bracket and port datums after welding.
Cleanliness
Debris control and protective caps reduce contamination risk before system flushing.
Variant Mix
Supply, return and rack-model variants require unmistakable part and kit identification.
Customer Project
Rack Liquid-Cooling Manifold: Pipe Support and Service Access
Materials, fabrication decisions and results for an anonymous customer project.
Component reference image
The Customer Challenge
Pipe vibration fatigued supports, joints leaked, and enclosure interference restricted maintenance access.
Project Measurements & Details
1.6 MPaWorking pressure
2.4 MPaTest pressure
≤300 mmSupport spacing
Results apply to the project configuration described on the linked page.
Read the Customer Project → 07 / Why Choose Us
Why Cooling OEMs Use DRAmetal for Rack Manifolds
01
Integrated metalwork
Headers, ports, brackets and guards can be coordinated under one released assembly.
02
Fixture-based inspection
Functional rack and port datums drive first-article and repeat checks.
03
Test traceability
Specified leak tests can be tied to assembly identity and revision.
04
Deployment kit control
Protected manifolds and hardware are grouped by rack, row and site.
08 / Related
Related Fabricated Products
09 / FAQ
Data Center Rack Manifolds FAQ
What is a rack manifold in direct liquid cooling?
It is the rack-level supply and return distribution assembly between the upstream cooling loop and server branches. It usually includes headers, ports, brackets and connection hardware.
Can you manufacture a custom DLC rack manifold?
Yes. We manufacture build-to-print headers and rack kits using drawing-defined materials, ports, joining methods, cleanliness controls and tests.
Do you select the manifold flow rate?
No. The system designer specifies flow, pressure drop, coolant and thermal requirements; we manufacture and inspect the released hardware.
What leak testing is available?
Testing can follow a released pressure, medium, hold time and acceptance criterion. The exact method must be defined on the drawing or quality plan.
What should a rack manifold RFQ include?
Send drawings, 3D models, rack datums, port and fitting specifications, materials, joining requirements, cleanliness level, test method, variants and quantities.
Get Started Need Rack Cooling Manifolds
Need Rack Cooling Manifolds
Matched to Your Cabinet?
Send rack and manifold drawings, port specifications, materials, tests, cleanliness requirements, variants and quantities for DFM review.