Cleanroom Production

Most common Areas of Application

The aim of our clean room production of plastics is to manufacture your series parts under reproducible conditions that are free of bacteria and germs. At 1zu1scale, depending on the project requirements, the entire production process can take place in an ISO Class 8 clean room. The clean room has separate material and personnel airlocks and is consistently designed for safe, standard-compliant clean room plastics technology.

Rapid Cleanroom Production with Plastic

Tight deadlines are part of our everyday routine – even in cleanroom production. By using aluminum tools, we can complete cleanroom plastic manufacturing projects almost as quickly as under standard conditions. This significantly speeds up testing, validation, and market launches.

However, depending on the component requirements, steel tools are also used. These are particularly necessary when the geometry, choice of material, tight tolerances, or high quantities require it. In cleanroom production, steel tools ensure maximum service life, maximum dimensional accuracy, and consistently high component quality throughout the entire series production process.

The combination of aluminum and steel tools enables flexible cleanroom production of plastics – from near-series prefabrication to long-term series production. This shortens development times while ensuring robust, validatable manufacturing processes in an ISO Class 8 cleanroom without compromising on quality, cleanliness, or process reliability.

Injection Molding in the Clean Room

With the expanded cleanroom production at the Dornbirn site, 1zu1scale has access to all the possibilities of high-purity cleanroom plastic production. Three encapsulated ARBURG injection molding machines with 2 × 70 tons and 1 × 100 tons of clamping force enable the production of bacteria- and germ-free plastic components.

In a separate, non-visible ISO Class 8 production room, plastic parts are coordinated or sampled together with the customer before series production begins. Our clean room production covers a wide range of components:

• Very small components from 4–5 mm edge length (from 15 t clamping force)
• Larger plastic parts up to approx. DIN A5 (up to 160 t clamping force)

State-of-the-art clean room plastic technology guarantees consistent quality and maximum process stability.

Human Hygiene Factor

In addition to technology, people play a central role in cleanroom production. Our employees work according to the strictest hygiene regulations and wear sterile work suits, cleanroom or overshoes, hairnets, and face masks.

The following ensure consistent cleanroom conditions:

• Sophisticated filter and ventilation technology
• Laminar flow areas for workpiece removal and packaging
• Permanent monitoring of all relevant processes

Sterile products are packaged in primary and secondary packaging according to your specifications. Cleanliness, sterility, and germ contamination are checked before, during, and after cleanroom production using contact monitoring and are fully documented.

Cleanroom Production of Plastics – your Advantages at a Glance

• ISO-compliant clean room production ISO Class 8 according to ISO 14644-1
• Clean room production of plastics from prototype to series production
• Encapsulated injection molding machines (Arburg, 70/100 t) for reproducible precision parts
• Precision mechanical part geometries from approx. 20 mm to 150 mm edge length
• High process stability through laminar flow, HEPA filtration, and overpressure control
• Effective particle and germ reduction through controlled air quality and contact monitoring
• Validatable cleanroom plastic components with complete documentation
• Cleanroom-compliant material logistics with separate material and personnel airlocks
• Sterile double packaging and labeling according to customer-specific specifications
• Short throughput times thanks to integrated tool production and cleanroom production
• Transparent fixed-price calculation for maximum cost certainty