Research on the health and safety hazards of 3D printing is new and in development due to the recent proliferation of 3D printing devices. In 2017, the European Agency for Safety and Health at Work has published a discussion paper on the processes and materials involved in 3D printing, potential implications of this technology for occupational safety and health and avenues for controlling potential hazards. [1]
Emissions from fused filament printers [2] can include a large number of ultrafine particles [3] and volatile organic compounds (VOCs). [4] [5] [6] The toxicity from emissions varies by source material due to differences in size, chemical properties, and quantity of emitted particles. [4] Excessive exposure to VOCs can lead to irritation of the eyes, nose, and throat, headache, loss of coordination, and nausea and some of the chemical emissions of fused filament printers have also been linked to asthma. [4] [7] Based on animal studies, carbon nanotubes and carbon nanofibers sometimes used in fused filament printing can cause pulmonary effects including inflammation, granulomas, and pulmonary fibrosis when at the nanoparticle size. [8] A National Institute for Occupational Safety and Health (NIOSH) study noted particle emissions from a fused filament peaked a few minutes after printing started and returned to baseline levels 100 minutes after printing ended. [4] Workers may also inadvertently transport materials outside the workplace on their shoes, garments, and body, which may pose hazards for other members of the public. [9]
Laser sintering and laser beam melting systems for additive manufacturing have become more important recently. The Institute for Occupational Safety and Health (IFA) together with German social accident insurance institutions conducted a measurement program on inhalation exposure to hazardous substances during laser deposition welding and laser beam melting with alloyed steels and nickel-, aluminium- and titanium-based alloys. No chromium(VI) compounds were detected in the workplace air during the process when materials containing chromium were processed, and the assessment criteria were complied with during processes with the other metal powders. One reason for this is that the machines are usually operated with encapsulation or dust extraction in order to achieve the required product quality. Since many work steps before and after the process including the handling of powder or powdered parts are performed manually or semi-automatically, there are huge effects on the degree of inhalation exposure and the measured values vary broadly. It is therefore difficult to derive tailored measures for these processes. [10]
Carbon nanoparticle emissions and processes using powder metals are highly combustible and raise the risk of dust explosions. [11] At least one case of severe injury was noted from an explosion involved in metal powders used for fused filament printing. [12]
Additional hazards include burns from hot surfaces such as lamps and print head blocks, exposure to laser or ultraviolet radiation, electrical shock, mechanical injury from being struck by moving parts, and noise and ergonomic hazards. [13] [14] Other concerns involve gas and material exposures, in particular nanomaterials, material handling, static electricity, moving parts and pressures. [15]
Hazards to health and safety also exist from post-processing activities done to finish parts after they have been printed. These post-processing activities can include chemical baths, sanding, polishing, or vapor exposure to refine surface finish, as well as general subtractive manufacturing techniques such as drilling, milling, or turning to modify the printed geometry. [16] Any technique that removes material from the printed part has the potential to generate particles that can be inhaled or cause eye injury if proper personal protective equipment is not used, such as respirators or safety glasses. Caustic baths are often used to dissolve support material used by some 3D printers that allows them to print more complex shapes. These baths require personal protective equipment to prevent injury to exposed skin. [14]
Since 3D imaging creates items by fusing materials together, there runs the risk of layer separation in some devices made using 3D imaging. For example, in January 2013, the US medical device company, DePuy, recalled their knee and hip replacement systems. The devices were made from layers of metal, and shavings had come loose – potentially harming the patient. [17]
Hazard controls include using manufacturer-supplied covers and full enclosures, using proper ventilation, keeping workers away from the printer, using respirators, turning off the printer if it jammed, and using lower emission printers and filaments. Personal protective equipment has been found to be the least desirable control method, with a recommendation that it only be used to add further protection in combination with approved emission's protection. [4]
Although no occupational exposure limits specific to 3D printer emissions exist, certain source materials used in 3D printing, such as carbon nanofiber and carbon nanotubes, have established occupational exposure limits at the nanoparticle size. [4] [18]
As of March 2018, [update] the US Government has set 3D printer emission standards for only a limited number of compounds. Furthermore, the few established standards address factory conditions, not home or other environments in which the printers are likely to be used. [19]
Laser printing is an electrostatic digital printing process. It produces high-quality text and graphics by repeatedly passing a laser beam back and forth over a negatively charged cylinder called a "drum" to define a differentially charged image. The drum then selectively collects electrically charged powdered ink (toner), and transfers the image to paper, which is then heated to permanently fuse the text, imagery, or both, to the paper. As with digital photocopiers, laser printers employ a xerographic printing process. Laser printing differs from traditional xerography as implemented in analog photocopiers in that in the latter, the image is formed by reflecting light off an existing document onto the exposed drum.
Toner is a powder mixture used in laser printers and photocopiers to form the text and images on paper, in general through a toner cartridge. Mostly granulated plastic, early mixtures added only carbon powder and iron oxide, however, mixtures have since been developed containing polypropylene, fumed silica, and various minerals for triboelectrification. Toner using plant-derived plastic also exists as an alternative to petroleum plastic. Toner particles are melted by the heat of the fuser, and are thus bonded to the paper.
Selective laser sintering (SLS) is an additive manufacturing (AM) technique that uses a laser as the power and heat source to sinter powdered material, aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure. It is similar to selective laser melting; the two are instantiations of the same concept but differ in technical details. SLS is a relatively new technology that so far has mainly been used for rapid prototyping and for low-volume production of component parts. Production roles are expanding as the commercialization of AM technology improves.
Nanomaterials describe, in principle, materials of which a single unit is sized between 1 and 100 nm.
3D printing or additive manufacturing is the construction of a three-dimensional object from a CAD model or a digital 3D model. It can be done in a variety of processes in which material is deposited, joined or solidified under computer control, with the material being added together, typically layer by layer.
Carbon nanofibers (CNFs), vapor grown carbon fibers (VGCFs), or vapor grown carbon nanofibers (VGCNFs) are cylindrical nanostructures with graphene layers arranged as stacked cones, cups or plates. Carbon nanofibers with graphene layers wrapped into perfect cylinders are called carbon nanotubes.
Nanotoxicology is the study of the toxicity of nanomaterials. Because of quantum size effects and large surface area to volume ratio, nanomaterials have unique properties compared with their larger counterparts that affect their toxicity. Of the possible hazards, inhalation exposure appears to present the most concern, with animal studies showing pulmonary effects such as inflammation, fibrosis, and carcinogenicity for some nanomaterials. Skin contact and ingestion exposure are also a concern.
Ultrafine particles (UFPs) are particulate matter of nanoscale size (less than 0.1 μm or 100 nm in diameter). Regulations do not exist for this size class of ambient air pollution particles, which are far smaller than the regulated PM10 and PM2.5 particle classes and are believed to have several more aggressive health implications than those classes of larger particulates. Although they remain largely unregulated, the World Health Organization has published good practice statements regarding measuring UFPs.
Workplace health surveillance or occupational health surveillance (U.S.) is the ongoing systematic collection, analysis, and dissemination of exposure and health data on groups of workers. The Joint ILO/WHO Committee on Occupational Health at its 12th Session in 1995 defined an occupational health surveillance system as "a system which includes a functional capacity for data collection, analysis and dissemination linked to occupational health programmes".
Fused filament fabrication (FFF), also known as fused deposition modeling, or filament freeform fabrication, is a 3D printing process that uses a continuous filament of a thermoplastic material. Filament is fed from a large spool through a moving, heated printer extruder head, and is deposited on the growing work. The print head is moved under computer control to define the printed shape. Usually the head moves in two dimensions to deposit one horizontal plane, or layer, at a time; the work or the print head is then moved vertically by a small amount to begin a new layer. The speed of the extruder head may also be controlled to stop and start deposition and form an interrupted plane without stringing or dribbling between sections. "Fused filament fabrication" was coined by the members of the RepRap project to give an acronym (FFF) that would be legally unconstrained in its use.
Dustiness is the tendency of particles to become airborne in response to a mechanical or aerodynamic stimulus. Dustiness is affected by the particle shape, size, and inherent electrostatic forces. Dustiness increases the risk of inhalation exposure.
Toxicology of carbon nanomaterials is the study of toxicity in carbon nanomaterials like fullerenes and carbon nanotubes.
Intratracheal instillation is the introduction of a substance directly into the trachea. It is widely used to test the respiratory toxicity of a substance as an alternative to inhalation in animal testing. Intratracheal instillation was reported as early as 1923 in studies of the carcinogenicity of coal tar. Modern methodology was developed by several research groups in the 1970s. By contrast, tracheal administration of pharmaceutical drugs in humans is called endotracheal administration.
Pharyngeal aspiration is the introduction of a substance into the pharynx and its subsequent aspiration into the lungs. It is used to test the respiratory toxicity of a substance in animal testing. It began to be used in the late 1990s. Pharyngeal aspiration is widely used to study the toxicity of a wide variety of substances, including nanomaterials such as carbon nanotubes.
A variety of processes, equipment, and materials are used in the production of a three-dimensional object via additive manufacturing. 3D printing is also known as additive manufacturing, because the numerous available 3D printing process tend to be additive in nature, with a few key differences in the technologies and the materials used in this process.
The health and safety hazards of nanomaterials include the potential toxicity of various types of nanomaterials, as well as fire and dust explosion hazards. Because nanotechnology is a recent development, the health and safety effects of exposures to nanomaterials, and what levels of exposure may be acceptable, are subjects of ongoing research. Of the possible hazards, inhalation exposure appears to present the most concern, with animal studies showing pulmonary effects such as inflammation, fibrosis, and carcinogenicity for some nanomaterials. Skin contact and ingestion exposure, and dust explosion hazards, are also a concern.
Hazard substitution is a hazard control strategy in which a material or process is replaced with another that is less hazardous. Substitution is the second most effective of the five members of the hierarchy of hazard controls in protecting workers, after elimination. Substitution and elimination are most effective early in the design process, when they may be inexpensive and simple to implement, while for an existing process they may require major changes in equipment and procedures. The concept of prevention through design emphasizes integrating the more effective control methods such as elimination and substitution early in the design phase.
A radioactive nanoparticle is a nanoparticle that contains radioactive materials. Radioactive nanoparticles have applications in medical diagnostics, medical imaging, toxicokinetics, and environmental health, and are being investigated for applications in nuclear nanomedicine. Radioactive nanoparticles present special challenges in operational health physics and internal dosimetry that are not present for other substances, although existing radiation protection measures and hazard controls for nanoparticles generally apply.
The characterization of nanoparticles is a branch of nanometrology that deals with the characterization, or measurement, of the physical and chemical properties of nanoparticles. Nanoparticles measure less than 100 nanometers in at least one of their external dimensions, and are often engineered for their unique properties. Nanoparticles are unlike conventional chemicals in that their chemical composition and concentration are not sufficient metrics for a complete description, because they vary in other physical properties such as size, shape, surface properties, crystallinity, and dispersion state.
Titanium dioxide nanoparticles, also called ultrafine titanium dioxide or nanocrystalline titanium dioxide or microcrystalline titanium dioxide, are particles of titanium dioxide with diameters less than 100 nm. Ultrafine TiO2 is used in sunscreens due to its ability to block ultraviolet radiation while remaining transparent on the skin. It is in rutile crystal structure and coated with silica or/and alumina to prevent photocatalytic phenomena. The health risks of ultrafine TiO2 from dermal exposure on intact skin are considered extremely low, and it is considered safer than other substances used for ultraviolet protection.
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