Germany ISO 6 Modular Cleanroom Project Overview
AIRKEY successfully completed a 31.5㎡ ISO 6 modular cleanroom for an optical component manufacturer in Germany. Designed specifically for precision glass moulding and optical production, the cleanroom provides a stable contamination-controlled environment that supports the manufacturing of high-precision optical components while ensuring consistent product quality and production efficiency.
Built to ISO 6 (Class 1,000) standards, the project combines modular construction with customized environmental control and intelligent cleanroom features. The compact design allows the client to maintain strict cleanliness requirements while maximizing production flexibility and minimizing installation time.
Client Background
The client, Vitrum Technologies, specializes in advanced glass moulding systems and optical manufacturing technologies. The company develops production solutions for aspherical optical components, free-form optics, wafers, and other precision glass products that require exceptional dimensional accuracy and surface quality.
Because optical manufacturing demands extreme precision throughout every production stage, maintaining a clean production environment is essential for achieving consistent optical performance and manufacturing reliability.
Why Optical Component Manufacturing Requires a Cleanroom
Optical component production is highly sensitive to airborne particles and environmental contamination. Even microscopic contaminants can permanently affect the quality and performance of finished optical products.
During precision glass moulding, particles remaining on the mould or glass surface may become permanently embedded into the softened material, creating irreversible surface defects.
Before optical coating, dust or organic contaminants can reduce coating adhesion or even cause coating delamination. Because optical coatings are typically measured in nanometers, even tiny particles can disrupt coating uniformity and generate unwanted light scattering.
During precision inspection, dust particles on optical surfaces may be mistaken for scratches or defects, resulting in inaccurate quality assessments, unnecessary product rejection, and reduced production efficiency. A stable cleanroom environment is therefore essential throughout the entire manufacturing process.
Premium Modular Cleanroom Construction
The cleanroom is constructed using high-quality sandwich panel walls that provide smooth, seamless surfaces in compliance with ISO cleanroom standards.
A dedicated pass-through chamber was installed to enable safe material transfer while reducing contamination risks. Personnel access is provided through automatic swing doors equipped with wave-to-open sensors, allowing completely hands-free operation and minimizing contact with cleanroom surfaces.
To maintain ISO 6 cleanliness, the project utilizes energy-efficient EC Fan Filter Units (FFUs) that provide stable airflow and reliable environmental control.
Switchable Privacy Glass for Flexible Production
One of the project's distinctive features is the installation of switchable privacy glass windows throughout the cleanroom.
Using remote control, the windows can instantly change between transparent and opaque modes. During confidential production processes, the opaque mode protects sensitive manufacturing activities from external visibility. When transparency is required, the windows provide a clear view of cleanroom operations, making routine inspections, maintenance, and customer visits more convenient.
This solution combines production confidentiality with operational efficiency while enhancing the overall appearance of the modular cleanroom.
Customized Air Conditioning and Environmental Monitoring
To provide stable environmental conditions, AIRKEY designed a customized ceiling-mounted cassette air conditioning system specifically for the cleanroom.
The mounting locations were pre-engineered during factory production, allowing rapid installation on site. The air conditioning system works together with the return air wall panels to improve airflow circulation and energy efficiency.
An online particle counter continuously monitors airborne particle levels to ensure the cleanroom consistently maintains ISO 6 cleanliness throughout production.
Removable Wall Panels for Equipment Installation
The client's manufacturing process requires the installation and maintenance of large production equipment.
To simplify future equipment upgrades, AIRKEY designed the modular cleanroom with removable wall panels that can be installed or removed manually without heavy tools. This design allows oversized equipment to enter or exit the cleanroom quickly while preserving the structural integrity of the entire cleanroom system.
The modular approach also reduces maintenance time and provides greater flexibility for future production line modifications.
Factory-Tested Performance for Reliable Operation
Before shipment, the complete modular cleanroom was fully assembled and thoroughly tested at AIRKEY's manufacturing facility.
All cleanroom components underwent comprehensive quality inspections, while key operational parameters—including cleanliness, airflow velocity, and illumination—were verified to ensure compliance with project specifications before delivery.
Factory acceptance testing significantly reduced commissioning time and ensured the cleanroom achieved reliable performance immediately after installation, providing the client with a dependable and efficient manufacturing environment.
