Introduction: The critical need for cleanliness in PCB manufacturing
In the precision-driven world of printed circuit board (PCB) manufacturing, even microscopic contaminants can lead to catastrophic failures such as short circuits, poor solderability, and reduced reliability. For processes like high-resolution printing, including solder mask and legend printing, a controlled environment is not a luxury but a necessity. This case study explores how Airkey, a leading cleanroom manufacturer in China, partnered with a PCB industry leader to deploy a turnkey, modular cleanroom solution that guarantees product quality and process stability.
Project overview and client challenge
Our client, a specialist in advanced PCBs, required an isolated, contaminant-free zone for their critical printing process. The challenge was to install a high-performance cleanroom within an existing facility with minimal disruption, while meeting stringent specifications for air cleanliness, temperature control, and material and personnel flow. In addition, the modular cleanroom needed to be easily expandable in the future to accommodate production growth or new process lines, protecting the client’s long-term investment.
Our solution: A bespoke, scalable and self-contained modular cleanroom system
We designed and built a free-standing, modular cleanroom with dimensions of 7.1 m (L) x 7.5 m (W) x 3.36 m (H). This room-within-a-room approach allowed for rapid deployment with minimal disruption to the client’s ongoing production. A core design philosophy was future-proofing. The entire structure is inherently expandable. The aluminium frames are reserved with installation holes, allowing the client to seamlessly expand the cleanroom’s footprint in the future to accommodate production growth or new process lines, protecting their long-term investment.
Key technical specifications
The cleanroom meets ISO 6 (Class 1000) cleanliness per ISO 14644-1. The structure consists of a high-strength aluminium alloy frame with insulated sandwich panels, ensuring structural integrity, thermal insulation, and airtight sealing. Integrated air conditioning units provide precise temperature and humidity management, which is crucial for printing consistency. A sophisticated fan filter unit ceiling system delivers HEPA-filtered clean air uniformly. Contaminated air is efficiently extracted through flush-mounted return air panels at lower levels, creating a consistent laminar downward flow to sweep particles away from the product. The system balances fresh air intake with filtered return air, based on detailed engineering calculations, to maintain positive pressure and optimal air changes per hour.
Innovative features for contamination control and logistics
Beyond the shell, critical contamination control airlocks were integrated. A personnel air shower provides a mandatory decontamination step for operators, removing particles from clothing before entry. A dynamic pass-through box allows raw materials, such as boards and inks, to be transferred into the cleanroom without compromising the internal environment, maintaining ISO 6 integrity. A conveyor air shower tunnel is a standout feature for automation. This tunnel cleanses the conveyor belt and products as they exit, preventing outbound contamination and enabling seamless integration into the next production step.
This project exemplifies Airkey’s commitment to providing not just cleanrooms, but tailored manufacturing ecosystems. By combining robust modular construction with precise environmental engineering, Airkey solves specific industry challenges. Whether for PCB printing, semiconductor assembly, or medical device manufacturing, Airkey delivers the controlled environment your process demands. Contact Airkey today to discuss how ISO-certified modular cleanrooms can enhance production quality and efficiency. Website: www.airkeyx.com
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