21 May Automotive Cleanrooms: Definition, Design, and Standards

Without adequate protection during manufacturing in the auto industry, recalls, safety issues, and legal problems may arise. The auto industry is no stranger to dangers of all kinds, and it’s for this exact reason that parts must be handled safely throughout the manufacturing process.

As parts get smaller and finer, more computerized, and more advanced, they also become more sensitive to small particles and even changes in static electricity. In other words, a small particle in the wrong place can ruin a part for good, and lead to safety issues in the vehicle it ends up in.

As a result, cleanrooms are often used during the manufacturing process. They help create a controlled space where vulnerable parts can be built without the risk of outside dangers.

In this guide, we’ll go over why cleanrooms are used in the automotive industry, where they’re most important, how they’re built, and the standards they need to meet.

Why the Automotive Industry Needs Cleanrooms

These days, automotive cleanrooms aren’t only needed for expensive or luxury vehicles. In fact, just about any vehicle today, regardless of whether it is electric or gas-powered, has many systems that require clean environments during production.

In other words, modern cars are filled to the brim with advanced and sensitive technology. This includes things like ADAS (advanced driver-assistance systems), computer systems of all kinds, as well as various sensors. Many of these parts can become damaged during the manufacturing process by dust or static electricity. Though it seems counter-intuitive, since a car ought to be full of all kinds of particles and fumes, during manufacturing these parts are much more vulnerable.

As a result, contamination can affect safety. If part of an airbag system malfunctions, for example, it can lead to catastrophes, both for the driver and for the company responsible.

Cleanrooms are also a way for the manufacturers of such parts to stay compliant with strict quality standards like ISO 14644-1. And in the long run, using cleanrooms can help reduce the possibility of product recalls and legal issues. When the manufacturing area is controlled, sensitive parts become more consistent and reliable.

Applications of Automotive Cleanrooms

Cleanrooms are used across the automotive industry wherever parts are vulnerable to dust, moisture, or static. Some common uses include:

• EV battery and fuel cell assembly: To prevent contamination during cell production.
• ADAS and sensor systems: To create clean environments for assembly and calibration.
• Semiconductors and printed circuit boards: To control static electricity and contamination that can damage parts.
• Paint booths: To help remove dust that may make finishes less smooth.

Automotive Cleanroom Design Considerations

The automotive industry, including both original equipment manufacturers (OEMs) and suppliers, is huge, to put it mildly. The type of cleanroom that each part may need to be in during its production will differ greatly. However, we can speak in general about some of the most basic design considerations for automotive cleanrooms.

1. Filtration and Air Flow

Automotive cleanrooms will likely use either HEPA or ULPA filters to remove airborne particles. Air filtration, as you might expect, is the most fundamental part of any cleanroom. It keeps particles under control in manufacturing spaces where contamination could affect parts and processes.

2. Environmental & Static Control

Cleanrooms keep things like temperature, humidity, and air pressure within specific ranges. This is extremely important for parts like batteries, sensors, and electronics, which can be harmed by heat or moisture. Many if not most rooms are kept at positive pressure to help keep particles out from surrounding areas.

Static is another important factor to watch. A small electric charge can ruin parts, especially small and sensitive ones like computer chips. To prevent this, cleanrooms often use special anti-static floors, grounded tools, and rules for how people move and use equipment.

3. Modular vs. Traditional Construction

Many automotive cleanrooms today are modular. They can be installed faster, are easy to modify later if need be, and don’t cause nearly as many disruptions to the manufacturing space. If production needs change down the line, which they often do, modular walls can be taken down or moved without starting from scratch. Traditional cleanrooms, on the other hand, still exist, but they’re slower to build and harder to adapt.

4. Materials and Finishes

Finally, there’s the consideration of surfaces in a cleanroom, which generally need to be smooth, non-shedding, and easy to clean. That goes for the walls, floors, ceiling panels, and also for work surfaces. You’ll often see materials like fiberglass-reinforced plastic, aluminum, steel, vinyl, and more.

Automotive Cleanroom Classifications & Standards

Cleanrooms are classified by the size of and number of particles are allowed in a given volume of air. The standard most often used is ISO 14644-1, which breaks cleanrooms into different classes, from ISO Class 1 (the cleanest) to ISO Class 9 (the “dirtiest”).

In the automotive industry, cleanrooms usually fall between ISO Class 5 and ISO Class 8, depending on what’s being made, of course. Very delicate processes, like semiconductor production, will require the strictest spaces, and basic coating or assembly work will fall on the other end of the spectrum.

The cleaner the room, the higher the classification that will be required (as well as higher cleanroom costs).

The Bottom Line

Cleanrooms are now a necessary part of many elements of automotive manufacturing. As parts get more advanced and more sensitive, the need for clean and controlled environments will only grow. Whether it’s for the electronics, batteries, or coatings, cleanrooms help keep vehicles safe during production and reduce the risk of failure later on.

Need a cleanroom for automotive manufacturing? Reach out to the experts at Allied Cleanrooms for a quote on new buildouts:

FAQs About Automotive Cleanrooms

1. Can a cleanroom be added to an already existing automotive manufacturing space?

Yes, they can. Cleanrooms, and especially modular ones, are often installed within working manufacturing spaces. The panels can even be brought through existing doors, and they can be freestanding or built against existing walls.

2. How long does it take to build an automotive cleanroom?

Unfortunately, it’s hard to estimate without knowing the exact details of the job. Modular cleanrooms, however, can often be designed and installed within a few weeks to a few months. Everything depends on the complexity of the job, so the simpler it is, the faster it can be delivered. If you go with a traditional cleanroom, it may take months or years to finish.

3. Do all automotive cleanrooms need to control static electricity?

No, definitely not. Whether you need to control static will depend upon whether electro-static discharge can damage the products/equipment you’re using in the space. If the parts include electronics, sensors, or semiconductors, then most likely yes. But for assembly or non-electronic parts, it may not be required at all.