Cleanroom injection molding refers to the manufacture of injection molded parts within an enclosed and tightly controlled environment to minimize the risk of contamination by airborne and surface pollutants and particulates. The cleanrooms employed in these operations vary in the degree to which they remove contaminants from the enclosed workspace and can be separated into nine ISO classifications levels, increasing in cleanliness from Class 1 to Class 9. Industry professionals—especially those from the medical, electronics, and defense industries—frequently use the process to produce sensitive plastic parts and products that are free from contamination.
Design Considerations for Cleanrooms
When designing a cleanroom, there are several factors to consider to ensure the finished structure achieves and maintains the level of cleanliness required for the intended manufacturing operations. Some of the considerations to keep in mind include:
The ISO class of a cleanroom dictates the level of cleanliness it accommodates. This factor relies heavily on the type of products worked with and/or produced in the cleanroom.
A properly designed cleanroom should have positive airflow to maintain particulate levels below an acceptable threshold.
The integrated filtration system should be able to filter at least 99.95% of the particulates from the room.
The cleanroom should only be as big as needed to minimize construction costs while ensuring the finished structure meets all operational needs.
Any personnel that enters the cleanrooms should wear the proper masking outfits, including hair and shoe covers, facemasks, and full-body gowns, to prevent tracking in additional contaminants.
Electric vs. hydraulic equipment
Equipment can serve as a potential source of contamination. Using electric machines instead of hydraulic machines can prevent more particulates from being added into the air.
Storage and packaging materials
Some materials, such as cardboard and plastics, can produce airborne particulates. Avoiding bringing these materials into the cleanroom mitigates the risk of raising contamination levels.
Building and construction
The materials used to build the structure should be carefully considered to ensure non-reactivity with the other cleanroom components and processed materials. When constructing the cleanroom, care should be taken to properly seal each component to prevent leaks and fit the windows and frames flush against the walls to mitigate dust collection in corners.
Cleanroom Injection Molding Solutions From D&M Plastics
D&M Plastics is an ISO 9001 and ISO 13485 certified industry leader in the field of injection molding. We provide innovative, high-quality injection molding solutions to customers across a wide range of industries, including aerospace, automotive, defense, electronics, and medical. Equipped with an ISO Class 8 cleanroom and quality materials, our team can perform tightly controlled manufacturing operations that meet some of the strictest industry standards. Our adherence to material management and quality assurance protocols further ensures we deliver exceptional products.
We are capable of working one-on-one with each customer, from concept development to product implementation. With our scalable manufacturing process, we are prepared for anything from prototype manufacturing to high-volume production.