The project demonstrates how modular cleanroom engineering can meet the demanding cleanliness and operational requirements of advanced additive manufacturing while offering installation flexibility and energy efficiency.
A Compact, High-Performance Cleanroom
The cleanroom measures 8 meters in length, 6 meters in width, and 2.6 meters in internal height, providing a 48-square-meter workspace that achieves ISO 5 (Class 100) cleanliness. This classification is essential for 3D printing applications, where airborne particles can compromise part integrity, surface finish, and material properties. Unlike conventional cleanrooms that require suspension from building structures or extensive ceiling reinforcement, this unit is entirely free-standing. Its self-supporting aluminum framework carries all mechanical loads, allowing it to be installed on a standard industrial floor without any overhead anchorage. For a U.S. manufacturing facility where existing building geometry or ceiling strength may present constraints, this approach significantly reduces both lead time and construction disruption.
Full Ceiling Coverage with EC-Motor Fan Filter Units
To achieve ISO 5 cleanliness across the entire workspace, the ceiling is fully covered by fan filter units(FFUs). This configuration delivers unidirectional, HEPA-filtered airflow that continuously sweeps particles away from critical production areas. The FFUs are equipped with ECmotors, which offer substantial advantages over traditional AC motors. EC motors consume less energy, generate lower heat, and operate at reduced noise levels—an important consideration for operators working extended hours near the equipment. All FFUs are centrally controlled through a single controller that allows operators to adjust air speed uniformly or in zones. This centralised control simplifies daily operation and helps balance cleanliness requirements against energy consumption.
Designed for Material and Component Transfer
The cleanroom includes two specialised features for moving items in and out without compromising contamination control. A cargo air shower equipped with roll-up doors accommodates larger materials, equipment, or printed parts. Operators place items inside the air shower, where high-velocity HEPA-filtered air removes surface particles before the opposite door opens. The roll-up doors save space and provide quick, convenient access. A dynamic pass box complements the cargo air shower for smaller, frequent transfers, maintaining pressure differentials and minimising air exchange between the cleanroom and the outside environment.
Power Flexibility for 3D Printing Equipment
Recognising that 3D printers often require different electrical configurations, the cleanroom is outfitted with both single-phase and three-phase power outlets. This feature allows the client to connect various printers, post-processing equipment, and testing instruments without separate electrical retrofitting. The flexibility also accommodates future equipment changes as production scales up or new technologies are adopted.
Factory Pre-Assembly and Testing
Before shipment, the entire cleanroom was preassembled at Airkey's factory. Every component—walls, ceiling grid, FFUs, air shower, pass box, electrical outlets, and control system—was installed and tested in a controlled workshop environment. The FFUs were run to verify airflow uniformity, noise levels, and energy consumption. The cargo air shower and pass box were cycled repeatedly to confirm interlocking sequences. Power outlets were tested under load. By identifying and resolving any fitting or performance issues at the factory, Airkey ensured that the on-site assembly in the United States would be straight forward and free of unexpected modifications. For the client, this meant minimal disruption to their facility and a predictable path from delivery to operational readiness.
Project Takeaways
Size : 8 m (L) × 6 m (W) × 2.6 m (H)
Classification : ISO 5 (Class 100)
Structure : Fully free-standing, no ceiling suspension required
FFU coverage : Full ceiling coverage with HEPA filters
Material entry : Cargo air shower with roll-up doors; dynamic pass box
Quality assurance : Factory pre-assembly and full system testing before shipment
Contact Airkey today to discuss how our ISO-certified modular cleanrooms can enhance your production quality and efficiency.
Website:
www.airkeyx.com
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