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Purpose – This study aims to investigate the potential impacts of rapid prototyping systems on the health and safety of operators and the environment, a growing concern given its wide-spread use in industry and academia. Design/methodology/approach – Materials, processing and equipment features were used to identify potential health and safety risks and hazards, as well as environmental effects. Findings – The study concludes with a “best practices” guide for rapid prototyping laboratories and service bureaus. Originality/value – A thorough literature search revealed that Stephen M. Deak, the Rapid Prototyping Department Manager at Hasbro Inc., is the pioneer of the safety and health concerns in the rapid prototyping area. He is the only person to publish papers in this field in addition to these authors’ recent publications. His papers focused on the rapid prototyping laboratory safety guidelines and safe work practices in the rapid prototyping area.

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Material extrusion-type fused filament fabrication (FFF) 3-D printing is a valuable tool for education. During FFF 3-D printing, thermal degradation of the polymer releases small particles and chemicals, many of which are hazardous to human health. In this study, particle and chemical emissions from 10 different filaments made from virgin (never printed) and recycled polymers were used to print the same object at the polymer manufacturer’s recommended nozzle temperature (“normal”) and at a temperature higher than recommended (“hot”) to simulate the real-world scenarios of a person intentionally or unknowingly printing on a machine with a changed setting. Emissions were evaluated in a college teaching laboratory using standard sampling and analytical methods. From mobility sizer measurements, particle number-based emission rates were 81 times higher; the proportion of ultrafine particles (diameter <100 nm) were 4% higher, and median particle sizes were a factor of 2 smaller for hot-temperature prints compared with normal-temperature prints (all p-values <0.05). There was no difference in emission characteristics between recycled and virgin acrylonitrile butadiene styrene and polylactic acid polymer filaments. Reducing contaminant release from FFF 3-D printers in educational settings can be achieved using the hierarchy of controls: (1) elimination/substitution (e.g., training students on principles of prevention-through-design, limiting the use of higher emitting polymer when possible); (2) engineering controls (e.g., using local exhaust ventilation to directly remove contaminants at the printer or isolating the printer from students); (3) administrative controls such as password protecting printer settings and establishing and enforcing adherence to a standard operating procedure based on a proper risk assessment for the setup and use (e.g., limiting the use of temperatures higher than those specified for the filaments used); and (4) maintenance of printers.