Facilitating Safe FFF 3D Printing: A Prototype Material Case Study

Abstract

Three-dimensional (3D) printing has introduced a paradigm shift in the manufacturing world, and it is increasing in popularity. In cases of such rapid and widespread acceptance of novel technologies, material or process safety issues may be underestimated, due to safety research being outpaced by the breakthroughs of innovation. However, a definitive approach in studying the various occupational or environmental risks of new technologies is a vital part of their sustainable application. In fused filament fabrication (FFF) 3D printing, the practicality and simplicity of the method are juxtaposed by ultrafine particle (UFP) and volatile organic compound (VOC) emission hazards. In this work, the decision of selecting the optimal material for the mass production of a microfluidic device substrate via FFF 3D printing is supported by an emission/exposure assessment. Three candidate prototype materials are evaluated in terms of their comparative emission potential. The impact of nozzle temperature settings, as well as the microfluidic device’s structural characteristics regarding the magnitude of emissions, is evaluated. The projected exposure of the employees operating the 3D printer is determined. The concept behind this series of experiments is proposed as a methodology to generate an additional set of decision-support decision-making criteria for FFF 3D printing production cases.

Bioinspired Pattern-Driven Single-Material 4D Printing for Self-Morphing Actuators

“…Other composites are created in order to control the activation of the stimulus for various applications [13]. PLA, which is a biodegradable thermoplastic based on lactic acid that can be produced from renewable resources, such as corn and sugar beets, is easy to use, making it the preferred material for 4D printing and biomedical researchers [14,15].…”

Characterization and Sustainability Potential of Recycling 3D-Printed Nylon Composite Wastes

“…This technique can be simulated as a standard plastic extruder in which the material is pushed into the printing head, melts, and is extruded out through a nozzle to produce a thin filament instead of using injection molds [23]. The widely used polymer materials in FDM are acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and polycarbonate (PC) [24,25], but the most dominant is the biodegradable material, PLA. For manufacturing purposes, synthetic polymers are desirable due to their properties, including plastics, nylons, and polyesters.…”