Health and safety
Research on the health and safety concerns of 3D printing is new and in development due to the recent proliferation of 3D printing devices. In 2017 the European Agency for Safety and Health at Work has published a discussion paper on the processes and materials involved in 3D printing, potential implications of this technology for occupational safety and health and avenues for controlling potential hazards. Most concerns involve gas and material exposures, in particular nanomaterials, material handling, static electricity, moving parts and pressures.
A National Institute for Occupational Safety and Health (NIOSH) study noted particle emissions from a fused filament peaked a few minutes after printing started and returned to baseline levels 100 minutes after printing ended. Emissions from fused filament printers can include a large number of ultrafine particles and volatile organic compounds (VOCs).
The toxicity from emissions varies by source material due to differences in size, chemical properties, and quantity of emitted particles. Excessive exposure to VOCs can lead to irritation of the eyes, nose, and throat, headache, loss of coordination, and nausea and some of the chemical emissions of fused filament printers have also been linked to asthma. Based on animal studies, carbon nanotubes and carbon nanofibers sometimes used in fused filament printing can cause pulmonary effects including inflammation, granulomas, and pulmonary fibrosis when at the nanoparticle size.
As of March 2018, the US Government has set 3D printer emission standards for only a limited number of compounds. Furthermore, the few established standards address factory conditions, not home or other environments in which the printers are likely to be used.
Carbon nanoparticle emissions and processes using powder metals are highly combustible and raise the risk of dust explosions. At least one case of severe injury was noted from an explosion involved in metal powders used for fused filament printing. Other general health and safety concerns include the hot surface of UV lamps and print head blocks, high voltage, ultraviolet radiation from UV lamps, and potential for mechanical injury from moving parts.
The problems noted in the NIOSH report were reduced by using manufacturer-supplied covers and full enclosures, using proper ventilation, keeping workers away from the printer, using respirators, turning off the printer if it jammed, and using lower emission printers and filaments. At least one case of severe injury was noted from an explosion involved in metal powders used for fused filament. Personal protective equipment has been found to be the least desirable control method with a recommendation that it only be used to add further protection in combination with approved emissions protection.
Hazards to health and safety also exist from post-processing activities done to finish parts after they have been printed. These post-processing activities can include chemical baths, sanding, polishing, or vapor exposure to refine surface finish, as well as general subtractive manufacturing techniques such as drilling, milling, or turning to modify the printed geometry. Any technique that removes material from the printed part has the potential to generate particles that can be inhaled or cause eye injury if proper personal protective equipment is not used, such as respirators or safety glasses. Caustic baths are often used to dissolve support material used by some 3D printers that allows them to print more complex shapes. These baths require personal protective equipment to prevent injury to exposed skin.
Although no occupational exposure limits specific to 3D printer emissions exist, certain source materials used in 3D printing, such as carbon nanofiber and carbon nanotubes, have established occupational exposure limits at the nanoparticle size.
Since 3-D imaging creates items by fusing materials together, there runs the risk of layer separation in some devices made using 3-D Imaging. For example, in January 2013, the US medical device company, DePuy, recalled their knee and hip replacement systems. The devices were made from layers of metal, and shavings had come loose Ė potentially harming the patient.