Fused Filament Fabrication 3D Printing: Quantification of Exposure to Airborne Particles

Abstract

Fused Filament Fabrication (FFF) has been established as a widely practiced Additive Manufacturing technique, using various thermoplastic filaments. Carbon fibre (CF) additives enhance mechanical properties of the materials. The main operational hazard of the FFF technique explored in the literature is the emission of Ultrafine Particles and Volatile Organic Compounds. Exposure data regarding novel materials and larger scale operations is, however, still lacking. In this work, a thorough exposure assessment measurement campaign is presented for a workplace applying FFF 3D printing in various setups (four different commercial devices, including a modified commercial printer) and applying various materials (polylactic acid, thermoplastic polyurethane, copolyamide, polyethylene terephthalate glycol) and CF-reinforced thermoplastics (thermoplastic polyurethane, polylactic acid, polyamide). Portable exposure assessment instruments are employed, based on an established methodology, to study the airborne particle exposure potential of each process setup. The results revealed a distinct exposure profile for each process, necessitating a different safety approach per setup. Crucially, high potential for exposure is detected in processes with two printers working simultaneously. An updated engineering control scheme is applied to control exposures for the modified commercial printer. The establishment of a flexible safety system is vital for workplaces that apply FFF 3D printing.

Integrating Exposure Assessment and Process Hazard Analysis: The Nano-Enabled 3D Printing Filament Extrusion Case

“…While there is a lack of available literature on exposure assessment during polymer extrusion, the potential for emission of UFPs and VOCs during thermal processing of thermoplastics has been documented extensively through studies on fused filament fabrication [40][41][42]. In our previous work [11], the potential for exposure to UFPs has been showcased for 3D printing of polymer matrices similar to the ones in the current study. Sub-micron concentration values were consistent with those presented above, with values quickly increasing at the start of material extrusion and gradually dropping closer to background throughout the process duration.…”

“…Nanosafety aspects related to occupational safety during the various life cycle stages of nanocomposite manufacturing (e.g., exposure of workers to released nanomaterials during compounding) may also be examined in the nanocomposite part use phase. Applications of nanocomposites that entail processing (e.g., thermal, mechanical) of the material during its use phase, such as the manufacturing of nanocomposite 3D printing filament, examined in the present study, ought to consider possible nanosafety concerns during the use phase to account for potential emissions during the 3D printing process [11].…”