Static mixer assemblies and related methods of fabrication and use

A method for fabricating a static mixer assembly comprising:

• providing a mixer body that extends from a first end to a second end, the first end having a first opening and the second end having a second opening, the mixer body including a first end member, a mixer portion, and a second end member, with the mixer portion having an internal mixer section;
• the first opening extending inward toward the mixer portion and in fluid communication with a first flow channel, and the second opening extending inward toward the mixer portion and in fluid communication with a second flow channel;
• the first flow channel extending from the first opening to a first manifold positioned proximal to a first end of the internal mixer section and the second flow channel extending from the second opening to a second manifold positioned proximal to a second end of the internal mixer section;
• the internal mixer section defining a lumen having an outer wall;
• and
• positioning a first, a second and a third plurality of grid members in the lumen, with the grid members of the first, second and third plurality of grid members each extending across the lumen from one side of the outer wall to another side of the outer wall;
• wherein the first and third plurality of grid members are positioned or oriented the same way across the lumen, thereby creating longitudinal mixing channels and transverse openings in the lumen relative to the first, second and third plurality of grid members;
• wherein the first and second manifolds each include one or more wedge members that are distinct from the grid members and are located at outermost grid members, at ends of the internal mixer section, to provide support to the outermost grid members.