Health and Safety During 3D Printing and Post-Processing

Additive manufacturing has revolutionized almost every industry that has adopted it, from automotive to medical. Additive manufacturing streamlines processes and adds unprecedented potential for any manufacturer in terms of innovation and performance. The flexibility and adaptability of these technologies have made additive an integral part of industry 4.0. But as with any manufacturing technology, manufacturers must factor health and safety into their operations.

With that in mind, Additive Conseil Sécurité recently conducted a study on print technologies and their impact on health and safety in an additive setting. Let’s examine some of the main takeaways from this in-depth analysis of health and safety in additive manufacturing.

Common Health and Safety Concerns for Post-Processing

Chemical Risks

The process of both 3D printing and post-processing often requires the use of heat. Heat interacts with the material or mixture and generates VOCs (volatile organic compounds), aerosols, and fine particles. Their specific toxicity is unknown, so technicians need protection from these airborne toxins to avoid the risk of chronic toxicity or even cancer. These particles are often classified as ultra-fine particles (UFPs), and they can pass through biological batteries. The human body has difficulty eliminating these UFPs, so proper safety gear is essential.?

Exposure to toxic solvents and solvent vapor can also be damaging. Solvents in contact with skin can cause irritation or burns. Prolonged and repeated exposure can lead to a skin rash, itching, dryness, and redness. Inhalation can cause anything from nose and throat irritation to dizziness, loss of coordination, and even unconsciousness.

Powder Risks

Some forms of 3D printing use polymer or metallic powders. These ultra-fine powders are a risk for a multitude of reasons in both the printing and post-processing of parts. Because of their texture, powders can easily disperse into the air, creating an inhalation risk. Metal powders fused in certain 3D print settings (L-PBF, EBM, L-LBM) generate an exceptionally high level of toxic emissions of nanoparticles.

Anoxia is a risk with gasses being generated from multiple different print technologies, along with solvents that are commonly used for post-processing. If the room’s oxygen level falls below 15%, asphyxia becomes a major risk.?

Risk of Explosion/Fire

The risk of explosion comes from a multitude of components used in the additive process. For one, the powders used in many technologies (SLS, MJF, DMLS, SLM) can be volatile. Plastic dust and metal powders can increase the risk of fire or explosion in an additive setting. Traditional solvents used for resin removal, like IPA, can also cause a fire or explosion because of IPA’s low flashpoint.

Musculoskeletal Disorders

Musculoskeletal disorders or MSDs are any injuries to the muscles, nerves, tendons, joints, cartilage, or spinal discs. Common disorders include tendonitis, arthritis, bone fractures, and carpal tunnel syndrome, to name a few.?

Worldwide, approximately 1.71 billion people suffer from musculoskeletal conditions [link]. In particular, water blasting and sanding with sandpaper during post-processing for surface finishing can cause musculoskeletal damage to the technician. Workstations must be set up ergonomically to avoid these harmful conditions.

MSDs constitute a significant factor in the workforce; in fact, MSDs have affected 100 million people in Europe and account for 60% of permanent work incapacity. What’s more, MSDs impact the overall gross domestic product (GDP) in both Europe and the US. about 15% of total losses in Europe are due to MSDs. In Germany, MSDs accounted for a whopping 17.2 billion in loss of production costs and 30.4 Billion in loss of labor productivity. The US also has felt the impact of MSDs on its workforce. It’s estimated that MSDs cost between $45-$54 Billion dollars annually in lost wages, compensation costs, and lost productivity.

Psychosocial Considerations

Outside of physical concerns, there are also psychosocial hazards to consider. Many workers can experience loneliness and isolation in the additive environment, especially if the additive space is small and windowless to help control environmental factors like temperature. Wearing a respirator for extended periods can also cause extreme discomfort to an individual. What’s more, with the manual labor required in traditional post-processing workflows, many technicians suffer from additional stress due to the diversity of materials, shapes, and batch sizes whose post-processing quality must be consistent and accurate.

Burnout is another common psychosocial consequence of additive’s traditionally labor-intensive post-processing step. Repetitive finishing is not only tough on technicians physically, but mentally as well.

Good Practice for the Health and Safety of Your Additive Post-Processing

When you decide to implement an additive manufacturing solution in your operation, there are many factors to consider. These are a few of the many health and safety considerations to address in an additive manufacturing environment. With this in mind, here are some ways to mitigate these potential risks, so you and your technicians have a positive, safe environment to work in. Always refer to your local safety authority for an extensive list of regulations required when working with any hazardous chemicals or materials.?

Machine Maintenance

It’s important to keep your machines well-maintained and to have inspections regularly. Inspections will help verify all parts of your machine are in good working order, including safety features.

Prioritize Technology

Prioritize technologies that remove dangerous materials and products from the additive process in favor of products with reduced impact on users and the environment. For example, machines can help eliminate harmful solvents in post-processing, automated systems that reduce the amount of technician time at the machine, and systems that use bio-sourced materials. Recent technological innovations have come on the market for post-processing can also mitigate risks associated with traditional post-processing methods.?

Collective Protective Equipment

Collective Protective Equipment, or CPE, is a device that offers a safety precaution to several workers who are susceptible to certain hazards. CPE can help reduce the frequency of incidents or accidents in a work environment. For example, a ventilation system in the space where print operations and post-processing occur would alleviate hazards.?

Personal Protective Equipment

Personal Protective Equipment, also known as PPE, is another way to maintain a safe and healthy work environment. Common examples of PPE are gloves, safety glasses or goggles, fine dust filter masks, antistatic footwear, fireproof clothing, and lab coats or boiler suits. Each print technology and post-processing workflow will require a different level of PPE.

Training

Training your employees on proper handling of chemicals and powders and proper machine operation is integral to maintaining a safe environment. All staff should have training on safety practices (like fire extinguishers), chemical risks, laser risks, and electrical risks.?

Manage Chemical Risks

Properly storing chemicals and correctly labeling them in their original containers is also important. Safety Data Sheets (SDS) should also be accessible to all employees. A system that captures pollutants at the source is essential to preserve your employee’s health.

Mitigating risks with additive will always be an ongoing process for any manufacturer. Familiarizing yourself with the rules and regulations in your region, along with implementing technology such as automation, especially with post-processing, will significantly improve working conditions for your employees.?

For additional information, download Additive Conseil Sécurité’s complete study here.