The cleanroom, measuring 7 metres in length, 4.5 metres in width and 3.3 metres in height, was engineered to meet the demanding requirements of optics manufacturing, where airborne particles and environmental fluctuations can directly affect product quality. Headquartered in Alsdorf, Germany, this company supplies forming systems for aspheric and free-form lenses, mirror substrates and other complex glass components.
Large-span, column-free construction
One of the defining features of the project is its fully self-supporting modular structure. The cleanroom uses an aluminium alloy frame with sandwich panels, designed to span the entire width without internal support columns or ceiling suspension. This column-free layout gives unobstructed floor space for production equipment and workflow, a critical advantage in optics manufacturing where machine layouts often require flexibility.
The walls are flush-mounted and smooth, with surfaces that resist particle generation- a fundamental requirement for maintaining ISO 6 cleanliness. Four wall panels were engineered as removable sections, allowing large-scale equipment to be moved in or out of the cleanroom when needed without dismantling the main structure.
Prefabrication and factory acceptance testing
As with Airkey’s earlier projects for European clients, the cleanroom was fully prefabricated, pre-assembled and subjected to rigorous performance testing at the company’s factory in China before shipment. This approach is consistent with Airkey’s established practice of validating modular cleanrooms prior to delivery, ensuring that on-site installation is rapid and that performance risks are eliminated at the manufacturing stage.
The testing regime included:
- airborne particle counts to certify ISO 6 classification,
- illumination level measurements,
- noise level assessments, and
- airflow velocity and uniformity verification.
All measurements were carried out using calibrated instruments from internationally recognised brands, with results documented to confirm compliance with ISO 14644-1 standards.
Smart access and adaptable visibility
The cleanroom is equipped with automatic swing doors fitted with wave sensors, allowing hands-free operation - a practical feature for personnel moving materials or working with delicate optical components. The doors are operated by automated door operators, reducing the need for manualcontact and minimising contamination risks.
A notable design element is the use of double-glazed privacy glass panels, which canbe switched between transparent and opaque states as required. This gives the ability to maintain visibility into the cleanroom during routine operations, while also providing privacy for sensitive development work when needed.
Energy-efficient air management
The cleanroom is served by a dedicated air-conditioning system to maintain a stable and comfortable working environment. Air is supplied through fan filter units mounted in the ceiling, each equipped with EC (electronically commutated) motors.
EC motors offer advantages over conventional AC alternatives, including lower power consumption, reduced heat output and quieter operation . The FFUs are centrally controlled, allowing operators to adjust airflow across the entire ceiling grid from a single interface, simplifying system management while maintaining uniform air distribution.
Key Project Highlights
- Column-free, large-span layout - clear span provides an unobstructed production floor, maximising flexibility for equipment arrangement and workflow.
- Adaptable enclosure - switchable privacy glass gives operators the choice of full visibility for supervision or an opaque mode for confidential development work.
- Future‑ proof access - four removable wall panels allow large - scale machinery to be moved in or out without dismantling the cleanroom.
- Hands-free hygiene - wave-to-open automatic doors reduce manual contact, supporting contamination control.
- Energy-saving air management - EC-motor FFUs with group control lower power consumption and noise while maintaining uniform laminar airflow.
- Factory-validated performance - every unit is pre-assembled and tested at Airkey’s facility with calibrated instruments, ensuring compliance with ISO 14644-1 before shipment.
