In the defence, space and life sciences industries, systems must be able to perform flawlessly in complex environments – whether this is in combat, in orbit or in a clinical setting.
Achieving a level of precision suitable for these critical and often cutting-edge applications requires manufacturing processes that eliminate contamination and consistently deliver quality products. Whilst the systems these markets require are destined for very different end uses, they all have one thing in common: cleanroom assembly is an essential part of the production process.
What is a cleanroom?
A cleanroom is a controlled environment designed to maintain extremely low levels of airborne particles, contaminants and pollutants. These rooms are engineered to meet strict standards for cleanliness and are essential for industries where even microscopic contamination can compromise product performance or safety.
The air in a cleanroom is filtered using HEPA (High-Efficiency Particulate Air) or ULPA (Ultra-Low Penetration Air) filters and is circulated in a laminar flow or turbulent flow pattern to prevent any build-up of particles. Variables including temperature, pressure and humidity are all controlled and continuously monitored. Anything entering the cleanroom is thoroughly cleaned, and the people who work there follow strict protocols and processes to minimise the chance of contamination.
How are cleanrooms classified?
Cleanrooms are classified based on the number of airborne particles per cubic metre. Different standards have been used over the years, but they have all been devised to define how cleanrooms should be designed, operated and monitored to prevent contamination. Today, ISO 14644-1 and ISO 14698 standards from the International Standards Organisation (ISO) are most commonly used in the UK and EU. In this system, ISO 1 is the cleanest. For example, ISO 1 is used in semiconductor assembly, while ISO 6 could be used for quadrupole assembly. The FED STD 209E standard was officially cancelled in 2001 but is still common to see this referenced e.g. ISO 14644-1 Class 6 (FED STD 209E Class 1,000).
What are the benefits of using a cleanroom?
Contamination Control
Cleanrooms provide an excellent foundation for contamination control. They are specifically designed to prevent dust, bacteria, and other contaminants to ensure that critical systems work reliably and accurately. Components are cleaned before they enter the room using specialist cleaning facilities.
Whilst the design of the space is important, the people who work in the cleanroom and how they conduct themselves is also a major factor in contamination control. Cleanroom engineers are highly skilled, and their main responsibility is to prevent contamination while performing specialised tasks. Cleanroom engineers follow carefully designed processes and wear specialist clothing to prevent skin flakes, hair and clothing fibres from contaminating the environment.
Compliance
Cleanrooms are regulated to ensure they meet a consistent level of cleanliness across the supply chain. The ISO level can be specified and regular certification and validation tests such as particle counting, airflow checks, and filter integrity assessments are carried out to demonstrate that the cleanroom consistently meets its classification requirements.
Consistency
Strict adherence to cleanroom procedures helps to ensure high yield and consistent quality. This is incredibly important across a number of industries including defence, space and life sciences.
What applications are cleanrooms used for?
Cleanrooms are used across a range of industries for many different applications. They are widely used in semiconductor and electronics manufacturing for producing microchips, integrated circuits, and optical components, where dust or static can cause defects. Defence and space applications rely on cleanrooms for assembling satellite components and guidance systems as well as high-end optics and laser systems to prevent contamination that could affect mission success. Sub-systems for analytical instruments like mass spectrometers are assembled in cleanroom environments. In the medical and pharmaceutical sectors, cleanroom environments ensure sterility during the production of implants, surgical instruments, and drug packaging. Biotechnology and life sciences also depend on cleanrooms for processes like DNA sequencing, cell culture, and tissue engineering to avoid microbial contamination. Â
What cleanroom facilities does Reliance Precision have?
At Reliance, clean assembly is one of our core production competencies. We have decades of experience in the manufacture and assembly of optical assemblies and sub-systems for analytical instruments and space applications. Our facilities are engineered to meet the requirements of the markets we serve and are supported by assembly engineers trained in both contamination control and precision assembly. Our facilities include:
Main Cleanroom
Our largest cleanroom is used for sub-systems designed for mass spectrometry applications. It is certified to ISO 14644-1 Class 6 (FED STD 209E Class 1,000).
Opto-Mechanical Cleanroom
Opto-mechanical assembly is undertaken in a dedicated cleanroom facility adhering to the necessary disciplines and processes appropriate to working with precision optics. It is certified to ISO 7 (FED STD 209E Class 10,000) and is supplemented by laminar flow cabinets to ISO 4 (FED STD 209E Class 10), together with certification to BS EN 61340.
Space Cleanroom
Our space cleanroom is certified to ISO 14644-1 Class 7 (FED STD 209E Class 10,000).
Cleaning Facilities
Our specialist cleaning facilities are used to clean components before they enter the cleanrooms. We have a fully enclosed solvent cleaning facility used to remove all traces of oil-based contaminants. Additional levels of cleanliness can be achieved using our automated aqueous cleaning line, acid cleaning, vacuum baking and plasma cleaning. Passivation and ultra-high vacuum (UHV) cleaning can also be carried out in-house.
Conclusion
As the defence, space and life sciences industries continue to push the boundaries of precision and performance in an ever-changing world, the controlled environment of a cleanroom ensures that every component and sub-assembly meets the highest standards of quality and safety. Cleanroom assembly is not just about compliance; it’s about safeguarding mission and process critical outcomes where failure is not an option.
Â
Reliance Precision has decades of experience in the assembly of life science sub-systems with applications ranging from mass spectrometry to photonics. If you require cleanroom assembly expertise, please contact us to discuss how we can support your mission or process critical goals.
