Space telescope receives ISO 5 cleanroom in 5 days

Construction of the 16 x 10 x 6 m large ISO 5 cleanroom.

The satellite in the completed cleanroom.

Airflow simulation of the cleanroom with Satellite.

Dipl.-Ing. (TU) Stefan Merkle, Managing Partner of Merkle CAE Solutions GmbH.

Creating an ISO 5 cleanroom environment is necessary for the construction of a space telescope. For the ESA mission PLATO, it was essential to realize this environment within an extremely short time frame. A consortium of seven highly qualified companies, along with state-of-the-art simulation technologies, made this unique challenge possible.

The space telescope, measuring 4 x 4 x 3 meters, equipped with 26 individual cameras as part of the ESA mission "PLATO," is designed to search the Milky Way for Earth-like planets. To ensure long-term functionality, the telescope is manufactured under cleanroom conditions; not only to account for the sensitivity of the optical systems. Contaminants can block electrical and mechanical contacts, impair thermal conductivity, or outgas in the vacuum of space, which can lead to problems over time.

For the planned satellite, an ISO class 5 cleanroom of approximately 16 x 10 x 6 meters was required. A time window of five days was allocated between the completion of construction and the start of satellite integration. Prior planning, realistic simulations, and close collaboration among the involved companies were crucial to success.

Merkle CAE Solutions GmbH prepared the strength verification of the support frame for the filter wall and the textile partitions based on FEM simulations and conducted detailed flow simulations, ensuring that the ISO 5 cleanroom class could be maintained effortlessly from the start. For this purpose, the fundamental airflow in the not-yet-constructed cleanroom was calculated. To avoid incoming particles from the surrounding air as well as recirculation effects, the satellite model itself was included in the calculations, to highlight only the most obvious issues. Optimization was carried out through multiple virtual variant studies until the best design for the layout of the filter wall was found.

"To realize such a demanding task within this tight time frame, professionals are needed. For all trades. We are very proud to have been part of this incredibly professional and ambitious team. This project once again demonstrates what simulation technology can achieve in the right hands. Especially with highly complex, sensitive, and time-critical tasks," said Dipl.-Ing. (TU) Stefan Merkle, Managing Partner of Merkle CAE Solutions GmbH.

OHB System AG is responsible as the client for the development and construction of the space telescope and its integration into the satellite. Merkle CAE Solutions GmbH developed the numerical simulation of the static support structure and the filter wall and created flow simulations to predict and optimize the cleanroom situation. QleanAir Scandinavia Austria was responsible for providing cleanroom solutions for the construction of the cleanroom. Hanselmann GmbH handled logistics and industrial assembly. Thetex GmbH & Co. KG supplied the cleanroom equipment, and Dorfner GmbH & Co. KG took care of building cleaning.