Managing the Health Risks of 3D Printing

In this article we explore the process of 3D printing and we identify the opportunities and the health implications that this exciting technology presents.

3D Printing is a modern technology where three dimensional objects are created from computer generated designs. It is not uncommon to find 3D printers in schools, universities, and public learning spaces as well as in multi-national manufacturing facilities. Since they have entered the consumer market 3D printers have led to “micro-factory industries” based out of bedrooms and garages across the world. These informal workplaces have presented new and interesting health and safety challenges.

we explore the process of 3D printing and identify the opportunities and the health implications that this exciting technology presents

How does 3D printing work?

Definition

The term 3D printing is possibly misleading in that it has become a catch-all word for different digital methods. These include milling machines, laser cutters, steel plotters and additive technologies. These methods may be similar in that they are digitally designed and robotically controlled, however where one method subtracts from solid materials i.e. milling and cutting from a raw piece of steel; the other involves the addition of layers of hot raw materials to build a piece from scratch. It is this “additive manufacturing” that is probably the most accurate description of 3D printing.

3D printing process

Designs for 3D models can be solely computer generated which eventually prepares a CAD file for printing. The other emerging method of designing objects is to use a 3D scanner which uses bouncing laser light on an existing object to reverse engineer the object, in order to generate workable designs to be sent to the 3D printer. The printer takes the digital designs and layers of plastic filament or metal powder, loads them into a printer, allows them to heat, and slowly creates an object that can range from a few grams to a quarter of a tonne. 3D printing can be small-scale printing or industrial-scale printing. The raw materials used in additive manufacturing can include:

• Polymer filaments
• Steel powder
• Glass beads
• Wood fibres
• Melted Foods
• Wax

The printer takes the digital designs and layers of plastic filament or metal powder, loads them into a printer, allows them to heat, and slowly creates an object that can range from a few grams to a quarter of a tonne

3D printing workplace risks

Minor safety risks

The main hazards associated with 3D printers are not safety related, but are actually health hazards. There are however safety risks associated with hot components, moving parts, and standard electrical risks. Where younger persons are involved the level of risk become elevated.

The 3D printer nozzle/head, which extrudes the melted material, can reach temperatures ranging between 200-300 degrees celsius. Some models have heated print beds which can range from 50-100 degrees celsius. Contact with these parts do pose a risk of severe skin burns. There are is also risks associated with freshly printed components which may also be hot enough to burn.

3D printers also have moving parts and these can be unprotected during operation. Loose clothing and long hair may become trapped in an operating printer. This poses a minor risk of pinches and entanglement between drive wheels and belts.

Chemical exposure

Pre-processing poses risks of exposure to irritant raw materials such as nickel, whilst some metal powders may be combustible. Post-processing tasks usually have elements of cleaning involved and exposure to chemicals presents irritant and corrosion hazards. These chemicals may be used to clean finished products and parts of the 3D printer. Surface treatment of semi-finished products can also involve exposure to sanding, paints, epoxy, and solvents. Solvents for example are known to affect the central nervous systems.

Harmful emissions

There are considerable health hazards associated with the exposure to emissions from heated filaments, polymers, and powders. Desktop 3D printers found in bedrooms and schools emit ultra-fine particles and moistures that may be carcinogenic or could cause other adverse health effects. The rate at which these particles are emitted, and are taken into the lungs and bloodstream have been compared to a cigarette burning in the room. The level of respiratory risk will depend on the raw material, the printing method itself, and on the size of the object being printed. A piece of furniture for example will generate significantly more emissions that a piece of jewellery.

Desktop 3D printers found in bedrooms and schools emit ultra-fine particles and moistures that may be carcinogenic or could cause other adverse health effects

Due to the semi-casual use of this technology the majority of homes and offices would likely fall below jurisdictional OEL requirements when the printer is in use. However at the the time of writing there are only a handful of countries with Occupational Exposure Limits (OEL) for 3D printing – and non existent standards and limits are difficult to enforce!

Casual work locations

3D printing is a disruptive technology that has redefined what a workplace can be. The changing and casual nature of locations where 3D enterprise takes place i.e. maker spaces, homes, and garages means that these “workplaces” lack industrial level ventilation, lighting, utilities, fire safety, and ergonomics. These elements are taken for granted in modern workplaces but 30 years ago the absence of safe working conditions was the root-cause of many types of occupational illness and injury. Again these types of regulations are proving difficult for authorities to enforce.

Occupational benefits of 3D printing

Leaner manufacturing knock-ons

Because traditional manufacturing is subtractive and 3D printing is additive, there is the potential to reduce waste material by as much as 70%. There are also power and labour efficiencies that go with this and a huge reduction in lead times for manufacturers. In short, 3D printing provides high-value products with a much smaller environmental footprint. This is has the added benefit of keeping jobs in-country, and less outsourcing of dangerous conditions to low-wage countries.

Reduced risk exposure

3D printing introduced a “do-it-yourself” movement. This democratisation of design, production, and distribution has had a positive side-effect for occupational health and safety. 3D printing presents fewer physical safety risks due to minimal machine/worker interface and a significant reduction in manpower. In short, these machines demand little manual involvement.

3D printing presents few physical safety risks due to minimal machine/worker interface and a significant reduction in manpower

Comment

3D printing is a disruptive technology that has redefined what a workplace can be. It has introduced manufacturing into schools, libraries and homes, and at an industrial level has reduced many of the risks associated with traditional manufacturing. These wins may however be traded-off with the loss of control over casual workplace conditions.

Much of the risks presented by 3D printing are health-related due to worker exposure to harmful emissions associated with heated materials, and chemicals. High quality consumer printers such as the ELEGOO MARS UV 3D Printer and the higher spec Dremel Digilab 3D20 have meant that garages, homes, libraries and classrooms have now become workplaces. These spaces are not equipped to deal with the emissions and fumes generated from 3D printing, nor do they meet work industrial workplace standards. Where 3D printers are used for commercial gain or for educational use, the owners may observe the following measures to mitigate associated risks:

Actionable information

Note: 3D printing safety is your responsibility. Always follow the printer manufacturers directions. You should use the above information as general advice.

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