Angstrom Tech, Author at Angstrom Technology

How to Set Up a Semiconductor Manufacturing Cleanroom

by Angstrom Tech | Oct 26, 2021 | Cleanroom Installation

Semiconductors are extremely sensitive materials. So without a controlled cleanroom to manufacture the chips in, you risk contamination that could lead to various production issues and product failures.

If your facility manufactures semiconductor chips for computerized devices of any type, size, or application, you’ll need a semiconductor manufacturing cleanroom. Let’s take a look at what components and considerations go into designing one.

Where to Start: Understanding the Requirements of a Semiconductor Cleanroom

Even the slightest bit of contamination or settling of particulate produce can ruin semiconductor production and performance, sometimes leading to disastrous consequences. Therefore, it’s important to understand the strict cleanliness standards that semiconductor cleanrooms must abide by.

Semiconductor Cleanroom Classifications

Even the slightest bit of contamination or settling of airborne particles can compromise semiconductor manufacturing efforts — leading to costly product defects. So before you get started designing your semiconductor manufacturing cleanroom, you should gain a thorough understanding of the threats they’re faced with and the cleanliness standards they must abide by.

Semiconductor Manufacturing Threats

When working in a semiconductor manufacturing cleanroom, operators face a number of challenges regarding detailed processes and contamination control. In fact, human workers themselves are often the main source of contamination during the semiconductor manufacturing process. Aside from particulate matter from their bodies and clothing, they can create unwanted electro-static discharge (ESD) that can ruin electronic circuits in the material.

Other than that, there are a number of additional environmental threats that can disrupt the semiconductor manufacturing process:

Static
Humidity
Airborne particles
Power glitches
Pressure malfunctions
Equipment outgassing
Dropped equipment, tools, and parts

Yes — that’s a lot to keep in mind! But semiconductors are so fragile that even the tiniest speck of dust can destroy them.

Fortunately, a reliable, controlled cleanroom can do most of the work for you. When designed, built, and installed properly, your semiconductor manufacturing cleanroom can maintain the level of environmental control you need to optimize productivity and profitability.

Discover the perfect semiconductor cleanroom setup banner

When You’re Ready: 4 Steps to Designing a Semiconductor Manufacturing Cleanroom

Now that you’re aware of the threats your semiconductor manufacturing cleanroom faces and the standards it needs to meet to prevent them, it’s time to start on design. Below we’ve outlined four considerations you’ll want to keep in mind during the design process.

1. Start with Cleanroom Airflow & Air Filtration

Airflow and air filtration are two of the most important aspects of great semiconductor manufacturing cleanroom design. They both determine how many airborne particles travel into your cleanroom and how they’re prevented from building up on equipment and materials. Let’s break them down one by one.

Cleanroom Airflow

ISO 14644-4 describes recommended cleanroom airflow patterns at various classification levels. The most popular (and widely recommended) airflow pattern is unidirectional, or laminar. It involves air blown at a constant speed in a straight and unimpeded path. The air is pushed through a filter (usually in the cleanroom ceiling) and then directed down toward the floor. To reduce turbulence, some semiconductor cleanrooms have raised flooring that use perforated tiles that allow air to flow through holes where it can be retreated and filtered before entering the cleanroom again.

Cleanroom Air Filtration

Cleanroom air filtration is all about how many airborne particles, and of which sizes, are permitted within a cleanroom. Regulations for this are documented in the ISO 14644-1 classification system.

Airborne particles are controlled with specialized air filtration systems, such as HEPA and ULPA filters. You can learn more about these systems and how they work on our air filtration page.

2. Consider Cleanroom Furniture and Machinery Placement

Semiconductor manufacturing requires various types of furniture, machinery, and equipment. It’s a good idea to map out where these items will be placed in order to produce the most efficient airflow patterns.

One of the best recommendations for semiconductor manufacturing cleanroom design is to place large furniture, machinery, and equipment along the outer walls. This helps decrease the chance of those big objects obstructing the main airflow.

Many cleanrooms are also designed with wire racks and shelves instead of regular shelving. This eliminates a portion of flat surfaces that contaminants can build up on.

3. Implement Anti-Static Protection

Electro-static discharge (ESD) can ruin semiconductors’ conductive properties. To prevent ESD, your semiconductor manufacturing cleanroom must take preventative measures. Cleanroom wall panels, flooring, furniture, and more should be manufactured with static dissipative materials. You may also include various ESD-free products like clothing, tools, and cleaning materials.

4. Plan For Daily Operations

In order to keep production moving and meet consumer demands, your semiconductor manufacturing cleanroom will likely be used daily. It’s important to design the cleanroom in a way that fits your operational plan. Make sure to note the following:

How your operators enter and exit the cleanroom
What ESD tests, gowning regimens, airlock rooms, and air showers your operators need to pass through before entry
How your operators move from task to task within the cleanroom
How often your operators need to clean the cleanroom, and what that process looks like

This information will help ensure your cleanroom is designed to maximize efficiency and cleanliness — which leads to better production quality, safety, and profitability.

Design a Semiconductor Manufacturing Cleanroom with Angstrom Technology

Need help getting started on your semiconductor manufacturing cleanroom design? Let the experts at Angstrom Technology help. Our design team can help you make the tough choices and ensure you get the robust solution that’s perfect for your application.

Request a semiconductor manufacturing cleanroom quote today, or contact us for more information.

Medical Cleanroom Technology that Aids Surface Sterilization

by Angstrom Tech | Oct 22, 2021 | Cleanroom Terminology

In order to keep operators and consumers safe, medical cleanrooms have some of the most stringent cleanliness requirements. Depending on whether they’re used for medical research, medical device, or pharmaceutical applications, their ISO standards can range from ISO Class 4-7.

All that being said, if your facility hosts one or more medical cleanrooms, you may also want to invest in some innovative technologies to ensure consistently sterilized air and surfaces. Below, we’ll explore some of the new medical cleanroom technology on the market, including various portable HEPA filtration systems and peroxide sanitizing solutions.

Portable HEPA Filtration Systems with UV-C Light Integration

While your cleanroom may already host a number of HEPA filters, some of the newest trends in medical cleanroom technology deem portable HEPA filters a rewarding investment. New portable HEPA filters can be mobile, ceiling mounted, or standalone, and they usually contain a UV-C light integrated for extra cleansing power. This way, you’re able to sterilize any specific area or surface more quickly and effectively than ever before.

How Do HEPA Filters with UV-C Light Integration Work?

HEPA filters are known for effectively capturing microscopic viruses and bacteria with ease. Generally, airborne viruses are moved through the air via particles with a diameter between 10-100 µm. HEPA filters are capable of capturing large infectious loads of particles that are responsible for virus transmission and exponentially reducing them.

HEPA filters can remove many of the common human pathogens from air circulation, including (but not limited to) the following:

Escherichia coli: Gastrointestinal infections
Aspergillus brasiliensis: Sinus infections
Mycoplasma pneumoniae: Pneumonia
Haemophilus influenzae: Meningitis
Mycobacterium Tuberculosis: Tuberculosis

When HEPA filters are combined with UV-C light technology, they can inactivate airborne-mediated microbial disease and microbial resistant bacteria even faster. UV-C lights and lamps are extremely effective, even against some of the most contagious airborne diseases. And while HEPA filters primarily cleanse the air, UV-C lights help sterilize water, hard surfaces, and nonporous objects as well.

Portable HEPA Filtration System Features and Accessories

Along with your portable HEPA filtration system, you’re able to add on a variety of optional features and accessories for advanced performance, including:

Portable UV torches – Portable UV disinfection torches are about 5 feet tall, and designed to sterilize objects and tools within a medical cleanroom. They stand on their own, include 8 UV-C bulbs, and are built with an open center that allows for comprehensive sterilization within a 10-foot radius.
Handheld UV light wands – Handheld UV light wands work similarly to portable UV torches, but are even more mobile. They have a lightweight, ergonomic design that is especially helpful in surface sanitation, and cleanroom inspection procedures.

Dry Hydrogen Peroxide

Dry Hydrogen Peroxide (DHP™) is the true gas form of hydrogen peroxide, and it attacks microbes like viruses, bacteria, and mold before they can be damaging, both in the air and on surfaces. Developed by Synexis, this technology is designed to flow freely and constantly throughout your controlled space to effectively eliminate pathogens — without any reliance on air exchange rates. It works by taking the oxygen and humidity naturally present in your environment, then breaking them down in the Synexis device through a photocatalytic reaction (chemical reaction involving the absorption of light). Those molecules are then put together again, but as DHP™.

Not only is DHP™ cool and effective technology, but it’s also completely safe — falling far below safety limits for human exposure established by OSHA and meeting UL2998 certification requirements for zero ozone emissions. You can learn more about how DHP™ works and benefits various applications here.

If you’re looking to upgrade your medical cleanroom technology to include some of the newest innovations, contact Angstrom Technology! Our cleanroom design experts can make sure your facility is outfitted with the best gadgets and gear to protect your work and workers.

Cleanroom Classification FAQs

by Angstrom Tech | Oct 19, 2021 | Cleanrooms

Cleanroom classification is often one of the most confusing parts of designing and building a cleanroom. However, it’s also one of the most essential parts, so it’s important that you understand all the relevant information. If you’re installing a cleanroom for the first time, you probably understand that every type of cleanroom requires a different classification, but you’re bound to have a number of other questions — and that’s okay! We’re here to help. Below, we’ll provide answers to some of the most common cleanroom classification questions we receive.

1. What are cleanroom classifications?

Cleanroom classifications regulate a cleanroom’s degree of cleanliness. They’re defined by the allowed amount of contamination, by particle count and size, as well as the air change rates necessary to maintain that. There are a variety of classification types that regulate cleanroom cleanliness, but the main system was developed by the International Standards Organization (ISO). ISO classifications apply to all cleanroom industries and applications, and range from Class 1 (most clean) to Class 9 (least clean, regular room air).

2. What cleanroom classification do I need?

It depends on your industry and application. The requirements will vary depending on the size of particles that need to be filtered, the sources of contamination present, and the recommended air change rates. If your industry is regulated by the government, you can check applicable regulations to see what cleanroom classification is required. If you work in a sector that isn’t regulated by the government and that doesn’t have an industry default, you’ll need to determine the appropriate classification for yourself, based on your application’s needs. Below, we’ll explore recommended cleanroom classifications for a few popular industries. For a full list of industries and their cleanrooms classifications, visit our cleanroom industries page.

What cleanroom classification is best for aerospace applications?

Aerospace applications require control over mechanical, thermal, chemical, and electrical properties within the cleanroom. In most cases, their cleanrooms need to meet at least a Class 7 ISO classification. However, in highly sensitive applications like spacecraft hardware, fine electronic, and optical device development, a more stringent classification is necessary.

What cleanroom classification is best for manufacturing applications?

There are various types of manufacturing processes, all with different needs in terms of humidity, contamination, pressure, and temperature control. However, most manufacturing cleanrooms tend to be required to meet ISO Classes 7 or 8.

What cleanroom classification is best for medical applications?

There are a few sub-categories that fall under the broad category of medical cleanrooms, including medical research, medical device, and pharmaceutical cleanrooms. All of these cleanrooms have some of the most stringent classifications in order to protect the safety of operators and consumers.

Medical research: ISO Class 5-7
Medical device: ISO Class 5-8
Pharmaceutical: ISO Class 5

What cleanroom classification is best for semiconductor applications?

Contamination is a large source of production issues and product failures in semiconductors and microelectronics, so it’s critical that the cleanrooms they’re manufactured and packaged in are filtered appropriately. In most cases, semiconductor cleanrooms will hold ISO Class 4-6 requirements.

3. How often should I test my cleanroom to see if it’s meeting classification requirements?

ISO requires that air pressure difference and airflow be tested every 12 months for all classifications. For ISO Classes 6-9, particle tests must also be performed every 12 months, but for ISO Classes 1-5, those particle tests must be performed every six months. The following tests are recommended for all ISO Classes, every 24 months:

Installed filter leakage
Containment filter leakage
Recovery
Airflow visualization

4. How often do I need to have my cleanroom inspected?

That depends on your cleanroom classification. The more stringent the classification, the more regular the inspections. Inspections may coincide with compliance testing, so they could occur every 6-12 months, depending on your specific requirements.

5. How does cleanroom classification affect my budget?

In general, the more stringent your cleanroom classification, the greater the cost. Strict classifications require more air, energy, advanced technology, and equipment, so their prices reflect that. For a more detailed breakdown of the costs, you can check out our blog, “How Does Cleanroom Classification Affect Your Cleanroom Budget?”

6. Can I redesign my cleanroom to fit a different classification?

Yes. Every facility’s needs change over time. A cleanroom from Angstrom Technology can change right along with them. All of our cleanrooms are “backward compatible,” meaning their size can expand or decrease and their fan filter units can be added or removed to keep up with any changes in cleanroom classification requirements. Have any questions about your cleanroom classification and how to reach it? Contact the experts at Angstrom Technology! We’re happy to walk through your specific requirements and help design and build the best cleanroom for your facility and application.

Understanding Cleanroom Costs by Type

by Angstrom Tech | Sep 29, 2021 | Cleanroom Terminology, Helpful Tips

If your facility needs a controlled space for one or more of its operations, you may be looking into purchasing a cleanroom. However, while doing your research, you may find yourself stuck on which type of cleanroom is the best investment for you: SoftWall, HardWall, or RigidWall?

Each of these cleanroom types has different characteristics and advantages, which naturally means that each of them are sold at different price points. In this article, we’ll explore the relative costs of these types of cleanrooms, as well as the value that each can bring to your facility.

SoftWall Cleanrooms – $

Generally, SoftWall cleanrooms are the most affordable cleanroom option. The low price point reflects their simple design and minimal use of materials.

However, just because SoftWall cleanrooms are the most affordable doesn’t mean that they lack quality. Their lightweight, powder-baked enamel framework and clear vinyl sheeting offers simple installation, maintenance, and customization to best fit the needs of your facility. Also capable of meeting cleanroom classification standards for ISO Class 4-8 and Federal 209E Class 10-100,000, SoftWall cleanrooms work great for many applications.

SoftWall cleanrooms are ideal for facilities that need to meet some classification and standards requirements, but don’t quite need to meet the highest standards or a tight temperature and humidity specification. As an affordable option that’s easy to assemble, maintain, and reconfigure, they can bring great value to large applications and custom cleanroom applications.

HardWall Cleanrooms – $$$

HardWall cleanrooms are usually the most expensive type of cleanroom, for good reason. Their higher price tags are accompanied by superior cleanroom performance, capable of meeting even the most stringent cleanliness standards.

HardWall cleanrooms are made from solid materials like stainless steel, vinyl, plastic laminate, aluminum, and fiberglass-reinforced plastic. These solid materials make them an extremely secure, treated, and durable solution for facilities that need an ultra-controlled environment.

With the ability to meet ISO Class 1-8 and Federal 209E Class 1-100,000 standards, HardWall cleanrooms are worth the investment if your facility’s applications require an extensive amount of control over factors like contamination, humidity, temperature, static, and pressure. No other type of cleanroom will provide that level of protection.

RigidWall Cleanrooms – $$$

RigidWall cleanrooms tend to fall in a similar price range as HardWall cleanrooms. They’re somewhat of a hybrid between the two types of cleanrooms previously mentioned. They have the same structural system as a SoftWall cleanroom, but instead of curtains, they use an extruded aluminum extrusion in conjunction with a 1/4 inch acrylic panel.

RigidWall cleanrooms can offer extreme versatility for a variety of applications. While they don’t offer quite as much stringency as a HardWall cleanroom, they do offer a good bit of control and provide a good show piece for potential customers. They offer contamination security to fit ISO Class 5-8 requirements and Federal 209E Class 100-100,000 requirements.

If your facility is looking for a cleanroom with good control, but also requires a certain level of aesthetics, a RigidWall cleanroom is a worthy investment for you. It’s a versatile solution with a structural system that can be adapted to fit the needs of your facility, and an environmental control factor that keeps your materials and operators safe — giving you some of the best of both worlds.

No matter what type of cleanroom you need, Angstrom Technology can help you design and install it to meet your classification and budget requirements. We’re experts in working with clients to find the solutions that best suit their facilities and applications. Reach out to our team to get started today.

How to Choose a Fan Filter Unit for your Cleanroom

by Angstrom Tech | Sep 21, 2021 | Air Circulation, Cleanroom Design, Cleanrooms, Filtration

In order to ensure your facility is meeting required cleanliness standards, fan filter units (FFU) are a critical component of your cleanroom design. Let’s explore more about fan filter units: how they work, what types there are, and how to choose the right one for your cleanroom.

What Is a Fan Filter Unit?

A fan filter unit is an independent filtration system mounted in a modular cleanroom ceiling grid that is used in conjunction with an air handling unit or HVAC system. It contains a fan, a pre-filter, and a filter (either HEPA or ULPA). In most cleanrooms, multiple fan filter units are installed in the cleanroom ceiling grid and are designed to provide a consistently treated workspace, minimizing dead zones.

Individual fan filter units can be added and subtracted according to the size and necessary ISO Class regulations. In general, the bigger your cleanroom, and the more stringent your ISO Class, the more fan filter units your cleanroom will likely need.

How Does a Fan Filter Unit Work?

Fan filter units work by continuously pushing clean, filtered air into your cleanroom. Air travels through a pre-filter, through the fan, and then through the HEPA or ULPA filter that treats and filters out airborne particles prior to entering your cleanroom.

When Do You Use a Fan Filter Unit for a Cleanroom?

Fan filter units provide a number of advantages over traditional air handling units. Here are a few reasons you may consider using fan filter units for your cleanroom:

Easy to install – Because they are mounted in the cleanroom ceiling grid, fan filter units are easy to install and are easily accessible from within the cleanroom.2
Easy to modify – As your facility grows and changes, your filtration system can too. Fan filter units can easily be added into the ceiling grid if you have to meet increased cleanliness requirements in the future.
Cost-effective – Fan filter units are generally less expensive than a completely new air system, both in terms of production cost and installation cost.

Types of Fan Filter Units: PSC vs. ECM

While all fan filter units function in generally the same way, there are two types of motors that commonly power a cleanroom FFU: permanent split capacitors (PSC) and electronically commutated motors (ECM). Each motor functions a little differently, providing distinct advantages depending on which option you choose. PSC motors operate at one consistent speed, while ECM motors have a variable speed drive and can adjust speed based on application requirements.

PSC vs. ECM: Which Fan Filter Unit is Right for Your Cleanroom?

Both of these are reliable options, guaranteed to provide the filtration your cleanroom needs. However, ECM units are often the best choice to help you meet your cleanroom goals and maximize treated space.

The Benefits of an ECM Fan Filter Unit

ECM fan filter units are known to be air-treating powerhouses for a range of applications — especially if those applications require varying filtration speeds. Its variable speed drive includes numerous benefits, including:

Smooth operation in inconsistent conditions
Great durability for big, long-haul projects
Energy-saving technology to help you reduce utility costs

Looking for a cleanroom that incorporates high performance filter fan units? Angstrom Technology can design a cleanroom to accommodate any equipment for your application. Contact us today to get started.