Emissions of Nanoparticles and Gaseous Material from 3D Printer Operation

Pulmonary and systemic toxicity in rats following inhalation exposure of 3-D printer emissions from acrylonitrile butadiene styrene (ABS) filament

BACKGROUND

Fused filament fabrication 3-D printing with acrylonitrile butadiene styrene (ABS) filament emits ultrafine particulates (UFPs) and volatile organic compounds (VOCs). However, the toxicological implications of the emissions generated during 3-D printing have not been fully elucidated.

AIM AND METHODS

The goal of this study was to investigate the in vivo toxicity of ABS-emissions from a commercial desktop 3-D printer. Male Sprague Dawley rats were exposed to a single concentration of ABS-emissions or air for 4 hours/day, 4 days/week for five exposure durations (1, 4, 8, 15, and 30 days). At 24 hours after the last exposure, rats were assessed for pulmonary injury, inflammation, and oxidative stress as well as systemic toxicity.

RESULTS AND DISCUSSION

3-D printing generated particulate with average particle mass concentration of 240 ± 90 µg/m³, with an average geometric mean particle mobility diameter of 85 nm (geometric standard deviation = 1.6). The number of macrophages increased significantly at day 15. In bronchoalveolar lavage, IFN-γ and IL-10 were significantly higher at days 1 and 4, with IL-10 levels reaching a peak at day 15 in ABS-exposed rats. Neither pulmonary oxidative stress responses nor histopathological changes of the lungs and nasal passages were found among the treatments. There was an increase in platelets and monocytes in the circulation at day 15. Several serum biomarkers of hepatic and kidney functions were significantly higher at day 1.

CONCLUSIONS

At the current experimental conditions applied, it was concluded that the emissions from ABS filament caused minimal transient pulmonary and systemic toxicity.

Emissions associated with operations of four different additive manufacturing or 3D printing technologies

In this pilot-scale study, a wide range of potential emissions were evaluated for four types of additive manufacturing (AM) machines. These included material extrusion (using acrylonitrile-butadiene-styrene [ABS]); material jetting (using liquid photopolymer); powder bed fusion (using nylon); and vat photopolymerization (using liquid photopolymer) in an industrial laboratory setting. During isolated operation of AM machines, adjacent area samples were collected for compounds of potential concern (COPCs), including total and individual volatile organic compounds (VOCs), nano- and micron-sized particulate matter, and inorganic gases. A total of 61 compounds were also sampled using a canister followed by gas chromatography and mass spectrometry analysis. Most COPCs were not detected or were measured at concentrations far below relevant occupational exposure limits (OELs) during AM machine operations. Submicron particles, predominantly nanoparticles, were produced during material extrusion printing using ABS at approximately 12,000 particles per cubic centimeter (p cm^-3) above background. After subtracting the mean background concentration, the mean concentration for material extrusion printing operations correlated with a calculated emission rate of 2.8 × 10¹⁰ p min^-1 under the conditions tested. During processing of parts produced using material jetting or powder bed fusion, emissions were generally negligible, although concentrations above background of respirable and total dust were measured during processing of powder bed fusion parts. Results of this pilot-scale study indicate that airborne emissions associated with AM operations are variable, depending on printing and parts handling processes, raw materials, and ventilation characteristics. Although personal samples were not collected in this pilot-scale study, the results can be used to inform future exposure assessments. Based on the results of this evaluation, measurement of submicron particles emitted during material extrusion printing operations and dust associated with handling parts manufactured using powder bed fusion processes should be included in exposure assessments.

Preparation of Hydrophobic Surface on PLA and ABS by Fused Deposition Modeling

In the fields of agriculture, medical treatment, food, and packaging, polymers are required to have the characteristics of self-cleaning, anti-icing, and anti-corrosion. The traditional preparation method of hydrophobic coatings is costly and the process is complex, which has special requirements on the surface of the part. In this study, fused deposition modeling (FDM) 3D printing technology with design and processing flexibility was applied to the preparation of hydrophobic coatings on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts, and the relationship between the printing process parameters and the surface roughness and wettability of the printed test parts was discussed. The experimental results show that the layer thickness and filling method have a significant effect on the surface roughness of the 3D-printed parts, while the printing speed has no effect on the surface roughness. The orthogonal experiment analysis method was used to perform the wettability experiment analysis, and the optimal preparation process parameters were found to be a layer thickness of 0.25 mm, the Grid filling method, and a printing speed of 150 mm/s.

The Analysis of 3D Printer Dust for Forensic Applications,

3D printers are becoming increasingly efficient and economical, and thus more widespread and easily accessible to consumers and businesses. They have been used to print nefarious objects such as guns and suppressors. Previous research has documented the release of dust particles during the printing process; however, little has been written about the morphology and chemical features that define the dust emitted by these printers. This study was undertaken to recover, analyze, and identify the dust produced during the printing process in the context of forensic trace evidence analysis. Samples were collected from a variety of 3D fused deposition modeler printers, representing both consumer and commercial grade models. This work focused on printers that use thermoplastic filaments composed of acrylonitrile butadiene styrene (ABS) or polylactic acid (PLA), two of the most commonly used filament polymers. Swabs were used to collect dust within the printer chamber and then processed to isolate the dust particles. Particles produced from ABS filaments are most easily recognized via light microscopy through a combination of color, morphology, and fluorescence. The composition of these particles can be confirmed through analysis by either FTIR or Raman microspectroscopy. These methods can also be used to identify ABS fillers and pigments within the printer dust particles. In contrast, dust from PLA printers consistently contained finer, submicron-sized particles that could be observed by field emission scanning electron microscopy. Because the size of the particles precludes their identification using vibrational spectroscopy methods, pyrolysis-GC-MS was used to confirm the presence of PLA.

Emissions of selected monoaromatic hydrocarbons as a factor affecting the removal of single-use polymer barbecue and kitchen utensils from everyday use

The main focus of this study is the emission of monoaromatic hydrocarbons because these are the preliminary factors of potential solvent and monomer residues present in single-use plastic barbecue and kitchen utensils comprising polystyrene, polypropylene, natural cellulose, and biodegradable polymers intended for use with hot meal or beverages. Herein, the emissions of monoaromatic hydrocarbons (styrene, benzene, toluene, ethylbenzene, and xylene compounds and the total volatile organic compounds (TVOC)) from nine types of disposable plastic utensils are reported. Seventy two samples of single-use plastic utensils were conditioned at 40 and 80 °C using a stationary emission microchamber system. The average TVOC released from the studied polystyrene, polypropylene, and natural or biodegradable utensils were (2.3 ± 1.3), (1.01 ± 0.15), and (0.48 ± 0.37) μg g^-1, respectively, at 40 °C and (11.1 ± 1.2), (46.1 ± 9.5), and (5.5 ± 1.1) μg g^-1, respectively, at 80 °C. Significant emissions of styrene (ranged from 3.5 up to 15.3 × 10³ ng∙g^-1), toluene (from 2.8 up to 0.53 × 10³ ng∙g^-1), and ethylbenzene (from 3.7 up to 5.7 × 10³ ng∙g^-1) from the studied samples were observed, especially at 80 °C. Thus, elevated temperatures increase the potential emission of solvent and monomer residues from plastics and could affect the quality of consumed meals or beverages, such as taste. Additionally, to determine the possible interactions between the measured chemical compounds in the plastic utensils, the Pearson's correlation coefficients were calculated.

Screening for extractables in additive-manufactured acrylonitrile butadiene styrene orthopedic cast

The use of additive-manufactured components in medical applications, specifically medical devices (e.g., orthopedic casts), has increased in recent years. Such devices may be fabricated at the point of care using consumer-grade additive manufacturing. Limited studies have been conducted to evaluate the extractable substances of these devices. Chemical characterization followed by toxicological risk assessment is one means of evaluating safety of devices. This study was designed to determine the extractables profile of additive-manufactured materials according to filament grade and post-processing method. Feedstocks for additive manufacturing were tested as filament and manufactured casts, while the cast from consumer-grade filament (CGF) was post-processed. Samples were extracted using three solvents of varying polarities. Extracts were analyzed by gas chromatography/mass spectrometry (GC/MS) and liquid chromatography/mass spectrometry (LC/MS) techniques. In GC/MS analysis, isopropanol extracts generated fewer compound identifications for USP Class VI filament (USPF)-based casts (3) compared with the respective filament (17) while hexane generated the most compound identifications for the finished cast manufactured from CGF. CGF was found to have the highest number of nonvolatile extractables for isopropanol (15) and hexane (34) by positive ion LC/MS. Additionally, CGF produced more non-polar extractables in hexane than the USPF. A known polymer byproduct and potential genotoxicant, styrene acrylonitrile (SAN) trimer, was one of the compounds identified in both GC/MS and LC/MS at quantities ranging from 19 to 270 μg g^-1. Overall these results suggested that the extractables profile was affected by the filament material, printing procedure, and post-processing method.

Emissions and health risks from the use of 3D printers in an occupational setting

The aim of this study was to determine concentrations of particulates and volatile organic compounds (VOCs) emitted from 3D printers using polylactic acid (PLA) filaments at a university workroom to assess exposure and health risks in an occupational setting. Under typical-case (one printer) and worst-case (three printers operating simultaneously) scenarios, particulate concentration (total and respirable), VOCs and formaldehyde were measured. Air samples were collected in the printing room and adjacent hallway. Size-resolved levels of nano-diameter particles were also collected in the printing room. Total particulate levels were higher in the worst-case scenario (0.7 mg/m³) vs. typical-case scenario (0.3 mg/m³). Respirable particulate and formaldehyde concentrations were similar between the two scenarios. Size-resolved measurements showed that most particles ranged from approximately 27 to 116 nm. Total VOC levels were approximately 6-fold higher during the worst-case scenario vs. typical situation with isopropyl alcohol being the predominant VOC. Airborne concentrations in the hallway were generally lower than inside the printing room. All measurements were below their respective occupational exposure limits. In summary, emissions of particulates and VOCs increased when multiple 3D printers were operating simultaneously. Airborne levels in the adjacent hallway were similar between the two scenarios. Overall, data suggest a low risk of significant and persistent adverse health effects. Nevertheless, the health effects attributed to 3D printing are not fully known and adherence to good hygiene principles is recommended during use of this technology.

Effect of nozzle temperature on the emission rate of ultrafine particles during 3D printing

Ultrafine particles and other hazardous materials are emitted during 3D printing, but the effect of temperature on such particles has not been studied systematically. The aim of this study was to evaluate the effect of temperature on the emission rate of particulate matter during fused deposition modeling (FDM) three-dimensional (3D) printing using different filament types. The number concentration of particles was measured with direct-reading instruments in an exposure chamber at various temperatures while using four filament materials during 3D printing. The temperature was increased from 185 to 290°C in 15°C increments, while incorporating the manufacturer-recommended operating conditions. The emission rate increased gradually as the temperature increased for all filament types, and temperature was the key factor affecting the emission rate after filament type. For all filaments, at the lowest operating temperature, the emission rate was 10⁷ -10⁹ particles/min, whereas the emission rate at the highest temperature was about 10¹¹ particles/min, that is, 100-10 000 times higher than the emission rate at the lowest temperature. To reduce particle emissions from 3D printing, we recommend printing at the lowest temperature possible or using low-emission materials.

Chemical and Physical Characterization of 3D Printer Aerosol Emissions with and without a Filter Attachment

Fused filament fabrication three-dimensional (3D) printers have been shown to emit ultrafine particles (UFPs) and volatile organic compounds (VOCs). Previous studies have quantified bulk 3D printer particle and VOC emission rates, as well as described particle chemical composition via ex situ analysis. Here, we present size-resolved aerosol composition measurements from in situ aerosol mass spectrometry and ex situ transmission electron microscopy (TEM). Particles were sampled for in situ analysis during acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) 3D printing activities and ex situ analysis during ABS printing. We examined the effect of a high-efficiency particulate air filter attachment on ABS emissions and particle chemical composition and demonstrate that filtration was effective in preventing UFP emissions and that particles sampled during filtered prints did not have a high contribution (∼4% vs ∼10%) from aromatic ions in the mass spectrum. Ex situ analysis of particles collected during ABS printing was performed via TEM and electron energy loss spectroscopy, which indicated a high level of sp² bonding type consistent with polymeric styrene. One 3D print with PLA resulted in an aerosol mass size distribution with a peak at ∼300 nm. Unfiltered ABS prints resulted in particle mass size distributions with peak diameters of ∼100 nm.

A review of 3D printing techniques for environmental applications

With a wide variety of techniques and compatible materials, three-dimensional (3D) printing is becoming increasingly useful in environmental applications in air, water, and energy. Through the advantages of quick production, cost-effectiveness, customizable design, the ability to produce complex geometries, and more, 3D printing has supported improvements to air quality monitors, filters, membranes, separation devices for water treatment, microbial fuel cells, solar cells, and wind turbines. It also supports sustainable manufacturing through reduced material waste, energy use, and carbon emissions. Applications of 3D printing within four environmental disciplines are described in this article: sustainable manufacturing, air quality, water and wastewater, and alternative energy sources.

Nanocluster Aerosol Emissions of a 3D Printer

Many studies exist that characterize the aerosol emissions from fused filament fabrication three-dimensional (3D) printers. However, nanocluster aerosol (NCA) particles, that is particles in a size range under 3 nm, are rarely studied. The purpose of this study was to characterize the NCA emissions and the contribution of NCA to the total particle number emissions from a 3D printer. We used a particle size magnifier and a scanning mobility particle sizer to measure the time evolution of particle size distribution, which was used to calculate the average NCA emission rates during a printer operation in a chamber. The NCA emission rates ranged from 1.4 × 10⁶ to 7.3 × 10⁹ s^-1 depending on the applied combination of filament material and nozzle temperature, showing increasing emission with increasing temperature. The NCA emissions constitute from 9 to 48% of the total emissions, that is, almost half of the particle emissions may have been previously neglected. Therefore, it is essential to include the low NCA size range in, for example, future 3D-printer-testing protocols, emission measurement standards, and risk management measures.

3D-Printed Lab-on-a-Chip Diagnostic Systems-Developing a Safe-by-Design Manufacturing Approach

The aim of this study is to provide a detailed strategy for Safe-by-Design (SbD) 3D-printed lab-on-a-chip (LOC) device manufacturing, using Fused Filament Fabrication (FFF) technology. First, the applicability of FFF in lab-on-a-chip device development is briefly discussed. Subsequently, a methodology to categorize, identify and implement SbD measures for FFF is suggested. Furthermore, the most crucial health risks involved in FFF processes are examined, placing the focus on the examination of ultrafine particle (UFP) and Volatile Organic Compound (VOC) emission hazards. Thus, a SbD scheme for lab-on-a-chip manufacturing is provided, while also taking into account process optimization for obtaining satisfactory printed LOC quality. This work can serve as a guideline for the effective application of FFF technology for lab-on-a-chip manufacturing through the safest applicable way, towards a continuous effort to support sustainable development of lab-on-a-chip devices through cost-effective means.

The characteristics and formation mechanisms of emissions from thermal decomposition of 3D printer polymer filaments

Ultrafine particles (UFP) and volatile organic compounds (VOC) emitted from fused deposition modelling (FDM) 3D printing have received widespread attention. Here, we characterize the formation mechanisms of emissions from polymer filaments commonly used in FDM 3D printing. The temporal relationship between the amount and species of total VOC (TVOC) at any desired operating thermal condition is obtained through a combination of evolved gas analysis (EGA) and thermogravimetric analysis (TGA) to capture physicochemical reactions, in which the furnace of EGA or TGA closely resembles the heating process of the nozzle in the FDM 3D printer. It is generally observed that emissions initiate at the start of the glass transition process and peak during liquefaction for filaments. Initial increment in emissions during liquefaction and the relatively constant decomposition of products in the liquid phase are two main TVOC formation mechanisms. More importantly, low heating rate has the potential to restrain the formation of carcinogenic monomer, styrene, from ABS. A TVOC measurement method based on weight loss is further proposed and found that TVOC mass yield was 0.03%, 0.21% and 2.14% for PLA, ABS, and PVA, respectively, at 220 °C. Among TVOC, UFP mass accounts for 1% to 5% of TVOC mass depending on the type of filaments used. Also, for the first time, emission of UFP from the nozzle is directly observed through laser imaging.

Evaluation of the Effect of an Exhaust Reduction System in Fire Stations

Firefighters are known to be exposed to a variety of hazardous materials and combustion products during operational and training activities, as well as in fire stations. However, exposure to diesel exhaust emissions, classified as carcinogenic to humans by the International Agency for Research on Cancer (IARC), is also present in the fire station environment. In this study, concentrations of elemental carbon (EC), which is a surrogate of diesel exhaust and indoor air pollutants, has been measured to compare the effect of an exhaust reduction system (ERS) that was installed in the engine bays of two fire stations to mitigate indoor air pollution levels in the garage, duty offices, and dormitory/shower areas. The levels of most pollutants were reduced after the installation of the ERS. Pollutants may disperse inside of fire stations. Therefore, the ERS is a valuable strategy to mitigate pollutant exposure among firefighters and outdoor air pollution using the filtration ability of an ERS. The results of this study suggest that all truck bays should install an ERS to reduce pollutant exposure and that installation is especially necessary for EURO 3 fire vehicles.

Particle and organic vapor emissions from children's 3-D pen and 3-D printer toys

Objective: Fused filament fabrication "3-dimensional (3-D)" printing has expanded beyond the workplace to 3-D printers and pens for use by children as toys to create objects.Materials and methods: Emissions from two brands of toy 3-D pens and one brand of toy 3-D printer were characterized in a 0.6 m3 chamber (particle number, size, elemental composition; concentrations of individual and total volatile organic compounds (TVOC)). The effects of print parameters on these emission metrics were evaluated using mixed-effects models. Emissions data were used to model particle lung deposition and TVOC exposure potential.Results: Geometric mean particle yields (106-1010 particles/g printed) and sizes (30-300 nm) and TVOC yields ( Collapse

Key Words

• 3-D printing
• children
• exposure
• particles
• toys
• volatile organic compounds

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MESH Headings

• Air Pollution, Indoor/analysis
• Child
• Environmental Monitoring/methods
• Humans
• Particle Size
• Particulate Matter/analysis
• Play and Playthings
• Printing, Three-Dimensional
• Volatile Organic Compounds/analysis

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Grants

• CC999999 Intramural CDC HHS
• R01 ES015022 NIEHS NIH HHS

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Affiliation(s)

Jinghai Yi Department of Physiology and Pharmacology, and the Center for Inhalation Toxicology, West Virginia University School of Medicine, Morgantown, WV, 26506
Matthew G. Duling National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Lauren N. Bowers National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Alycia K. Knepp National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Ryan F. LeBouf National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Timothy R. Nurkiewicz Department of Physiology and Pharmacology, and the Center for Inhalation Toxicology, West Virginia University School of Medicine, Morgantown, WV, 26506 National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Anand Ranpara National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Todd Luxton U.S. Environmental Protection Agency, Office of Research and Development, National Risk Management Research Laboratory, Cincinnati, OH, 45224
Stephen B. Martin National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Dru A. Burns National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Derek M. Peloquin Oak Ridge Institute for Science and Education, Oak Ridge, TN, 37830
Eric J. Baumann Pegasus Technical Services, Cincinnati, OH, 45268
M. Abbas Virji National Institute for Occupational Safety and Health, Morgantown, WV, 26505
Aleksandr B. Stefaniak National Institute for Occupational Safety and Health, Morgantown, WV, 26505

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Chemical Composition and Toxicity of Particles Emitted from a Consumer-Level 3D Printer Using Various Materials

Consumer-level 3D printers emit ultrafine and fine particles, though little is known about their chemical composition or potential toxicity. We report chemical characteristics of the particles in comparison to raw filaments and assessments of particle toxicity. Particles emitted from polylactic acid (PLA) appeared to be largely composed of the bulk filament material with mass spectra similar to the PLA monomer spectra. Acrylonitrile butadiene styrene (ABS), extruded at a higher temperature than PLA, emitted vastly more particles and their composition differed from that of the bulk filament, suggesting that trace additives may control particle formation. In vitro cellular assays and in vivo mice exposure all showed toxic responses when exposed to PLA and ABS-emitted particles, where PLA-emitted particles elicited higher response levels than ABS-emitted particles at comparable mass doses. A chemical assay widely used in ambient air-quality studies showed that particles from various filament materials had comparable particle oxidative potentials, slightly lower than those of ambient particulate matter (PM_2.5). However, particle emissions from ABS filaments are likely more detrimental when considering overall exposure due to much higher emissions. Our results suggest that 3D printer particle emissions are not benign and exposures should be minimized.

Acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) filaments three-dimensional (3-D) printer emissions-induced cell toxicity

During extrusion of some polymers, fused filament fabrication (FFF) 3-D printers emit billions of particles per minute and numerous organic compounds. The scope of this study was to evaluate FFF 3-D printer emission-induced toxicity in human small airway epithelial cells (SAEC). Emissions were generated from a commercially available 3-D printer inside a chamber, while operating for 1.5 h with acrylonitrile butadiene styrene (ABS) or polycarbonate (PC) filaments, and collected in cell culture medium. Characterization of the culture medium revealed that repeat print runs with an identical filament yield various amounts of particles and organic compounds. Mean particle sizes in cell culture medium were 201 ± 18 nm and 202 ± 8 nm for PC and ABS, respectively. At 24 h post-exposure, both PC and ABS emissions induced a dose dependent significant cytotoxicity, oxidative stress, apoptosis, necrosis, and production of pro-inflammatory cytokines and chemokines in SAEC. Though the emissions may not completely represent all possible exposure scenarios, this study indicate that the FFF could induce toxicological effects. Further studies are needed to quantify the detected chemicals in the emissions and their corresponding toxicological effects.

Particle and vapor emissions from vat polymerization desktop-scale 3-dimensional printers

Little is known about emissions and exposure potential from vat polymerization additive manufacturing, a process that uses light-activated polymerization of a resin to build an object. Five vat polymerization printers (three stereolithography (SLA) and two digital light processing (DLP) were evaluated individually in a 12.85 m3 chamber. Aerosols (number, size) and total volatile organic compounds (TVOC) were measured using real-time monitors. Carbonyl vapors and particulate matter were collected for offline analysis using impingers and filters, respectively. During printing, particle emission yields (#/g printed) ranged from 1.3 ± 0.3 to 2.8 ± 2.6 x 108 (SLA printers) and from 3.3 ± 1.5 to 9.2 ± 3.0 x 108 (DLP printers). Yields for number of particles with sizes 5.6 to 560 nm (#/g printed) were 0.8 ± 0.1 to 2.1 ± 0.9 x 1010 and from 1.1 ± 0.3 to 4.0 ± 1.2 x 1010 for SLA and DLP printers, respectively. TVOC yield values (µg/g printed) ranged from 161 ± 47 to 322 ± 229 (SLA printers) and from 1281 ± 313 to 1931 ± 234 (DLP printers). Geometric mean mobility particle sizes were 41.1-45.1 nm for SLA printers and 15.3-28.8 nm for DLP printers. Mean particle and TVOC yields were statistically significantly higher and mean particle sizes were significantly smaller for DLP printers compared with SLA printers (p < 0.05). Energy dispersive X-ray analysis of individual particles qualitatively identified potential occupational carcinogens (chromium, nickel) as well as reactive metals implicated in generation of reactive oxygen species (iron, zinc). Lung deposition modeling indicates that about 15-37% of emitted particles would deposit in the pulmonary region (alveoli). Benzaldehyde (1.0-2.3 ppb) and acetone (0.7-18.0 ppb) were quantified in emissions from four of the printers and 4-oxopentanal (0.07 ppb) was detectable in the emissions from one printer. Vat polymerization printers emitted nanoscale particles that contained potential carcinogens, sensitizers, and reactive metals as well as carbonyl compound vapors. Differences in emissions between SLA and DLP printers indicate that the underlying technology is an important factor when considering exposure reduction strategies such as engineering controls.

Insights Into Emissions and Exposures From Use of Industrial-Scale Additive Manufacturing Machines

BACKGROUND

Emerging reports suggest the potential for adverse health effects from exposure to emissions from some additive manufacturing (AM) processes. There is a paucity of real-world data on emissions from AM machines in industrial workplaces and personal exposures among AM operators.

METHODS

Airborne particle and organic chemical emissions and personal exposures were characterized using real-time and time-integrated sampling techniques in four manufacturing facilities using industrial-scale material extrusion and material jetting AM processes.

RESULTS

Using a condensation nuclei counter, number-based particle emission rates (ERs) (number/min) from material extrusion AM machines ranged from 4.1 × 1010 (Ultem filament) to 2.2 × 1011 [acrylonitrile butadiene styrene and polycarbonate filaments). For these same machines, total volatile organic compound ERs (μg/min) ranged from 1.9 × 104 (acrylonitrile butadiene styrene and polycarbonate) to 9.4 × 104 (Ultem). For the material jetting machines, the number-based particle ER was higher when the lid was open (2.3 × 1010 number/min) than when the lid was closed (1.5-5.5 × 109 number/min); total volatile organic compound ERs were similar regardless of the lid position. Low levels of acetone, benzene, toluene, and m,p-xylene were common to both AM processes. Carbonyl compounds were detected; however, none were specifically attributed to the AM processes. Personal exposures to metals (aluminum and iron) and eight volatile organic compounds were all below National Institute for Occupational Safety and Health (NIOSH)-recommended exposure levels.

CONCLUSION

Industrial-scale AM machines using thermoplastics and resins released particles and organic vapors into workplace air. More research is needed to understand factors influencing real-world industrial-scale AM process emissions and exposures.

Improving the electrospinning process of fabricating nanofibrous membranes to filter PM2.5

To mitigate PM2.5 emissions is becoming a pressing concern, because these particles pose a threat to public health. Evidence shows that bead-free nanofiber with diameter of <100 nm is more likely to capture the PM2.5, however, currently it is impossible to fabricate bead-free nanofiber with such diameter without introduction of other substances. To fabricate bead-free polyacrylonitrile (PAN) nanofibers with diameter of <100 nm, we improved the electrospinning process of membrane fabrication via design of experiment (DOE), and we then used these nanofibers to filter PM2.5 emissions from burning cigarettes and fused deposition modeling (FDM) three-dimensional (3D) printing. The DOE was based on a L₂₇ (3¹³) orthodoxy array, which consists of six controllable factors, that is, the concentration of solution, the spinning voltage, the rotating speed, the tip-to-collector distance, the flow rate of the syringe pump, and the electrospinning temperature, each of them has three levels. The results showed that the nanofibers of the least diameter (i.e., 77 nm) can be fabricated under the following condition: 8 wt% PAN solution, 12 kV voltage, 5000 r/min, 12 cm tip-to-collector distance, 0.6 ml/h flow rate, and 50 °C electrospinning temperature. Range analysis and analysis of variance (ANOVA) showed that the concentration of PAN solution has the most significant effect on the diameter, and their values are positively correlated. An examination in a two-chamber filtering device showed the PAN membrane with the least fiber diameter has a PM2.5 filtration efficiency of 99.26%. A filtration test on standard FDM 3D printing process showed the membrane has a PM2.5 removal efficiency of 81.16%. This work could mitigate PM2.5 emissions from cigarette tobacco and FDM 3D printing, and it would be used to other scenarios, such as industrial and traffic emissions.

VOC Emissions and Formation Mechanisms from Carbon Nanotube Composites during 3D Printing

A commercially available, 3D printer nanocomposite filament of carbon nanotubes (CNTs) and acrylonitrile-butadiene-styrene (ABS) was analyzed with respect to its VOC emissions during simulated fused deposition modeling (FDM) and compared with a regular ABS filament. VOC emissions were quantified and characterized under a variety of conditions to simulate the thermal degradation that takes place during FDM. Increasing the residence time and temperature resulted in significant increases in VOC emissions, and the oxygen content of the reaction gas influenced the VOC profile. In agreement with other studies, the primary emitted VOC was styrene. Multiple compounds are reported in this work for the first time as having formed during FDM, including 4-vinylcyclohexene and 2-phenyl-2-propanol. Our results show that printing 222.0 g of filament is enough to surpass the reference concentration for inhalation exposure of 1 mg/m³ according to the EPA's Integrated Risk Information System (IRIS). The presence of CNTs in the filament influenced VOC yields and product ratios through three types of surface interactions: (1) adsorption of O₂ on CNTs lowers the available O₂ for oxidation of primary backbone cleavage intermediates, (2) adsorption of styrene and other VOCs to CNTs leads to surface-catalyzed degradation, and (3) CNTs act as a trap for certain VOCs and prevent them from entering vapor emissions. While the presence of CNTs in the filament lowered the total VOC emission under most experimental conditions, they increased the emission of the most hazardous VOCs, such as α-methylstyrene and benzaldehyde. The present study has identified an increased risk associated with the use of CNT nanocomposites in 3D printing.

Particle emissions from fused deposition modeling 3D printers: Evaluation and meta-analysis

Fused deposition modeling (FDM) 3D printers, the most popular choice among home hobbyists, have been shown to release volatile organic chemicals (VOCs) and billions of airborne particles per minute, indicating the potential for consumer inhalation exposure and consequent health risks. Publications on FDM 3D printer emissions however, contain large heterogeneity of testing methods and analytical procedures making it difficult to reach overall conclusions for particle characteristics or particle number emission rates across the field. In this publication, data were collected over the printing time from 3D printer emission studies including particle count diameters (PCDs) (nanometers), particle number concentrations (PNCs) (particles/cm³), and particle number emission rates (PNERs) (particles min^-1). Despite heterogeneity in methods, the majority of particles released were reported as ultrafine in size (i.e., <100 nm) indicating that using both acrylonitrile butadiene styrene (ABS) and poly-lactic acid (PLA) may present a risk of exposure to respirable particles. Mean PNC emitted in 3D printing tests ranged over several orders of magnitude across publications with overall means of 300,980 particles/cm³ for ABS and 65,482 particles/cm³ for PLA. Although mean PNC data were available from only 7 of the 16 papers reviewed, ABS resulted in greater particle numbers than PLA suggesting increased exposure to ultrafine particles. A linear mixed model was fitted for mean PNCs to further explore the impact of nozzle temperature and filament material. Finally, the PNER calculation method especially regarding losses, varied widely across studies, and directly impacted the PNERs reported. To strengthen direct comparability of results going forward, it is recommended that standard emissions testing protocols be developed for FDM 3D printers and particle influxes and losses be more uniformly calculated.

Occupational exposure to gaseous and particulate contaminants originating from additive manufacturing of liquid, powdered, and filament plastic materials and related post-processes

The aim of this study was to measure the concentrations of gaseous and particulate contaminants originated from additive manufacturing operations and post-processes in an occupational setting when plastics were used as feedstock materials. Secondary aims were to evaluate the concentration levels based on proposed exposure limits and target values and to propose means to reduce exposure to contaminants released in additive manufacturing processes. Volatile organic compounds were sampled with Tenax TA adsorption tubes and analyzed with a thermo desorption gas chromatography-mass spectrometry instrument. Carbonyl compounds were sampled with DNPH-Silica cartridges and analyzed with a high-performance liquid chromatography device. Particles were measured with P-Trak instrument and indoor air quality was sampled with IAQ-Calc instrument. Dust mass concentrations were measured simultaneously with a DustTrak DRX instrument and IOM-samplers. Particle concentrations were highest (2070-81 890 #/cm³ mean) during manufacturing with methods where plastics were thermally processed. Total volatile organic compounds concentrations, in contrast, were low (113-317 µg/m³ mean) during manufacturing with such methods, and vat photopolymerization. However, total volatile organic compounds concentrations of material jetting and multi jet fusion methods were higher (1,114-2,496 µg/m³ mean), perhaps because of material and binder spraying, where part of the spray can become aerosolized. Chemical treatment of manufactured objects was found to be a severe volatile organic compounds source as well. Formaldehyde was detected in low concentrations (3-40 µg/m³) in all methods except for material jetting method, in addition to several other carbonyl compounds. Notable dust concentrations (1.4-9.1 mg/m³) were detected only during post-processing of powder bed fusion and multi jet fusion manufactured objects. Indoor air quality parameters were not found to be notably impacted by manufacturing operations. Only low concentrations (below 2 ppm) of CO were detected during several manufacturing processes. All studied additive manufacturing operations emitted potentially harmful contaminants into their environments, which should be considered in occupational additive manufacturing and workplace design. According to the measured contaminant levels it is possible that adverse additive manufacturing related health effects may occur among exposed workers.

Evaluation of emissions and exposures at workplaces using desktop 3-dimensional printer

There is a paucity of data on additive manufacturing process emissions and personal exposures in real-world workplaces. Hence, we evaluated atmospheres in four workplaces utilizing desktop "3-dimensional" (3-d) printers [fused filament fabrication (FFF) and sheer] for production, prototyping, or research. Airborne particle diameter and number concentration and total volatile organic compound concentrations were measured using real-time instruments. Airborne particles and volatile organic compounds were collected using time-integrated sampling techniques for off-line analysis. Personal exposures for metals and volatile organic compounds were measured in the breathing zone of operators. All 3-d printers that were monitored released ultrafine and fine particles and organic vapors into workplace air. Particle number-based emission rates (#/min) ranged from 9.4 × 109 to 4.4 × 1011 (n = 9samples) for FFF3-d printers and from 1.9 to 3.8 × 109 (n = 2 samples) for a sheer 3-d printer. The large variability in emission rate values reflected variability from the printers as well as differences in printer design, operating conditions, and feedstock materials among printers. A custom-built ventilated enclosure evaluated at one facility was capable of reducing particle number and total organic chemical concentrations by 99.7% and 53.2%, respectively. Carbonyl compounds were detected in room air; however, none were specifically attributed to the 3-d printing process. Personal exposure to metals (aluminum, iron) and 12 different organic chemicals were all below applicable NIOSH Recommended Exposure Limit values, but results are not reflective of all possible exposure scenarios. More research is needed to understand 3-d printer emissions, exposures, and efficacy of engineering controls in occupational settings.

Characterization of particulate and gaseous pollutants emitted during operation of a desktop 3D printer

The emission of ultrafine particles (UFP) and gaseous pollutants from 3D printing has been increasingly gaining attention in recent years due to potential health risks. The physical and chemical properties of the emitted particulate matter, however, remain unclear. In this study, we characterized these particles with a focus on their chemical composition and volatility, and measured the gaseous pollutants from desktop 3D printing in a standardized environmental test chamber. Eight types of filaments were tested, including ABS (acrylonitrile butadiene styrene), ASA (acrylonitrile styrene acrylate), HIPS (high impact polystyrene), PETG (polyethylene terephthalate glycol), and PCABS (polycarbonate & ABS). Particle size distribution (PSD), particle number concentration (PNC), particle chemical composition and particle volatility were measured. In addition, volatile and very volatile organic compounds (VOCs and VVOCs) emitted during 3D printing were analyzed. The specific emission rates (SERs) for particles in the size range of 5.6 to 560 nm ranged from 2.0 × 10⁹ (GLASS, a PETG-based filament) to 1.7 × 10¹¹ (ASA) #/min. The particle SERs for ABS were (4.7 ± 1.1) × 10¹⁰ #/min. The SERs for total volatile organic compounds (TVOC) varied from 0.2 μg/min (GLASS) to 40.5 μg/min (ULTRAT, an ABS-based filament). Particles started to evaporate extensively from 150 °C. At 300 °C, only 25% of the particle number remained with the size distribution mode peaked at 11 nm. The particles collected on the quartz filter were mainly composed of semi-volatile organic compounds (SVOCs) associated with the plasticizers, flame-retardants, antioxidants of the thermoplastics, and cyclosiloxanes which may be used as lubricants in the 3D printer.

3D printing of musculoskeletal tissues: impact on safety and health at work

Additive manufacturing (commonly referred to as 3D printing) created an attractive approach for regenerative medicine research in musculoskeletal tissue engineering. Given the high number of fabrication technologies available, characterized by different working and physical principles, there are several related risks that need to be managed to protect operators. Recently, an increasing number of studies demonstrated that several types of 3D printers are emitters of ultrafine particles and volatile organic compounds whose harmful effects through inhalation, ingestion and skin uptake are known. Confirmation of danger of these products is not yet final, but this provides a basis to adopt preventive measures in agreement with the precautionary principle. The purpose of this investigation was to provide a useful tool to the researcher for managing the risks related to the use of different kinds of three-dimensional printers (3D printers) in the lab, especiallyconcerning orthopedic applications, and to define appropriate control measures. Particular attention was given to new emerging risks and to developing response strategies for a comprehensive coverage of the health and safety of operators.

Characteristics of nanoparticle formation and hazardous air pollutants emitted by 3D printer operations: from emission to inhalation

Nanoparticle and HAP emissions from 3D printers and their deposition behavior in the human respiratory system were evaluated.

Three-dimensional printing with nano-enabled filaments releases polymer particles containing carbon nanotubes into air

Fused deposition modeling (FDM™) 3-dimensional printing uses polymer filament to build objects. Some polymer filaments are formulated with additives, though it is unknown if they are released during printing. Three commercially available filaments that contained carbon nanotubes (CNTs) were printed with a desktop FDM™ 3-D printer in a chamber while monitoring total particle number concentration and size distribution. Airborne particles were collected on filters and analyzed using electron microscopy. Carbonyl compounds were identified by mass spectrometry. The elemental carbon content of the bulk CNT-containing filaments was 1.5 to 5.2 wt%. CNT-containing filaments released up to 1010 ultrafine (d < 100 nm) particles/g printed and 106 to 108 respirable (d ~0.5 to 2 μm) particles/g printed. From microscopy, 1% of the emitted respirable polymer particles contained visible CNTs. Carbonyl emissions were observed above the limit of detection (LOD) but were below the limit of quantitation (LOQ). Modeling indicated that, for all filaments, the average proportional lung deposition of CNT-containing polymer particles was 6.5%, 5.7%, and 7.2% for the head airways, tracheobronchiolar, and pulmonary regions, respectively. If CNT-containing polymer particles are hazardous, it would be prudent to control emissions during use of these filaments.

Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes

This paper explores the specific energy consumption (SEC) and environmental impacts for typical additive manufacturing processes. Also, the paper examines the possibility that ensure the product quality while reducing energy consumption with experimental analysis. The results show that (1) the SEC of additive manufacturing processes is related not only to material characteristics but also to the process input parameters; (2) it is possible to increase the energy efficiency without reducing product quality by adjusting the process rate or selecting different materials; and (3) the global warming potential (GWP) result of AM processes indicates that the GWP is brought about principally by the energy production process. The information provided by this project can also be of benefit to life cycle assessment and other environmental impact assessment related to AM processes.

Case report of asthma associated with 3D printing

Background

Three-dimensional (3D) printing is being increasingly used in manufacturing and by small business entrepreneurs and home hobbyists. Exposure to airborne emissions during 3D printing raises the issue of whether there may be adverse health effects associated with these emissions.

Aims

We present a case of a worker who developed asthma while using 3D printers, which illustrates that respiratory problems may be associated with 3D printer emissions.

Case report

The patient was a 28-year-old self-employed businessman with a past history of asthma in childhood, which had resolved completely by the age of eight. He started using 10 fused deposition modelling 3D printers with acrylonitrile-butadiene-styrene filaments in a small work area of approximately 3000 cubic feet. Ten days later, he began to experience recurrent chest tightness, shortness of breath and coughing at work. After 3 months, his work environment was modified by reducing the number of printers, changing to polylactic acid filaments and using an air purifier with an high-efficiency particulate air filter and organic cartridge. His symptoms improved gradually, although he still needed periodic treatment with a salbutamol inhaler. While still symptomatic, a methacholine challenge indicated a provocation concentration causing a 20% fall in FEV1 (PC20) of 4 mg/ml, consistent with mild asthma. Eventually, his symptoms resolved completely and a second methacholine challenge after symptom resolution was normal (PC20 > 16 mg/ml).

Conclusions

This case indicates that workers may develop respiratory problems, including asthma when using 3D printers. Further investigation of the specific airborne emissions and health problems from 3D printing is warranted.

Acute health effects of desktop 3D printing (fused deposition modeling) using acrylonitrile butadiene styrene and polylactic acid materials: An experimental exposure study in human volunteers

3D printers are increasingly run at home. Nanoparticle emissions from those printers have been reported, which raises the question whether adverse health effects from ultrafine particles (UFP) can be elicited by 3D printers. We exposed 26 healthy adults in a single-blinded, randomized, cross-over design to emissions of a desktop 3D printer using fused deposition modeling (FDM) for 1 hour (high UFP-emitting acrylonitrile butadiene styrene [ABS] vs low-emitting polylactic acid [PLA]). Before and after exposures, cytokines (IL-1β, IL-6, TNF-α, INF-γ) and ECP in nasal secretions, exhaled nitric oxide (FeNO), urinary 8-isoprostaglandin F_2α (8-iso PGF_2α ), and self-reported symptoms were assessed. The exposures had no significant differential effect on 8-iso PGF_2α and nasal biomarkers. However, there was a difference (P < .05) in the time course of FeNO, with higher levels after ABS exposure. Moreover, indisposition and odor nuisance were increased for ABS exposure. These data suggest that 1 hour of exposure to 3D printer emissions had no acute effect on inflammatory markers in nasal secretions and urine. The slight relative increase in FeNO after ABS printing compared to PLA might be due to eosinophilic inflammation from inhaled UFP particles. This possibility should be investigated in further studies using additional biomarkers and longer observation periods.

Characterization and Control of Nanoparticle Emission during 3D Printing

This study aimed to evaluate particle emission characteristics and to evaluate several control methods used to reduce particle emissions during three-dimensional (3D) printing. Experiments for particle characterization were conducted to measure particle number concentrations, emission rates, morphology, and chemical compositions under manufacturer-recommended and consistent-temperature conditions with seven different thermoplastic materials in an exposure chamber. Eight different combinations of the different control methods were tested, including an enclosure, an extruder suction fan, an enclosure ventilation fan, and several types of filter media. We classified the thermoplastic materials as high emitter (>10¹¹ #/min), medium emitters (10⁹ #/min -10¹¹ #/min), and low emitters (<10⁹ #/min) based on nanoparticle emissions. The nanoparticle emission rate was at least 1 order of magnitude higher for all seven filaments at the higher consistent extruder temperature than at the lower manufacturer-recommended temperature. Among the eight control methods tested, the enclosure with a high-efficiency particulate air (HEPA) filter had the highest removal effectiveness (99.95%) of nanoparticles. Our recommendations for reducing particle emissions include applying a low temperature, using low-emitting materials, and instituting control measures like using an enclosure around the printer in conjunction with an appropriate filter (e.g., HEPA filter) during 3D printing.

Aerosol Emissions from Fuse-Deposition Modeling 3D Printers in a Chamber and in Real Indoor Environments

Three-dimensional (3D) printers are known to emit aerosols, but questions remain about their composition and the fundamental processes driving emissions. The objective of this work was to characterize the aerosol emissions from the operation of a fuse-deposition modeling 3D printer. We modeled the time- and size-resolved emissions of submicrometer aerosols from the printer in a chamber study, gained insight into the chemical composition of emitted aerosols using Raman spectroscopy, and measured the potential for exposure to the aerosols generated by 3D printers under real-use conditions in a variety of indoor environments. The average aerosol emission rates ranged from ∼10⁸ to ∼10¹¹ particles min^-1, and the rates varied over the course of a print job. Acrylonitrile butadiene styrene (ABS) filaments generated the largest number of aerosols, and wood-infused polylactic acid (PLA) filaments generated the smallest amount. The emission factors ranged from 6 × 10⁸ to 6 × 10¹¹ per gram of printed part, depending on the type of filament used. For ABS, the Raman spectra of the filament and the printed part were indistinguishable, while the aerosol spectra lacked important peaks corresponding to styrene and acrylonitrile, which are both present in ABS. This observation suggests that aerosols are not a result of volatilization and subsequent nucleation of ABS or direct release of ABS aerosols.

Capturing PM2.5 Emissions from 3D Printing via Nanofiber-based Air Filter

This study investigated the feasibility of using polycaprolactone (PCL) nanofiber-based air filters to capture PM2.5 particles emitted from fused deposition modeling (FDM) 3D printing. Generation and aggregation of emitted particles were investigated under different testing environments. The results show that: (1) the PCL nanofiber membranes are capable of capturing particle emissions from 3D printing, (2) relative humidity plays a signification role in aggregation of the captured particles, (3) generation and aggregation of particles from 3D printing can be divided into four stages: the PM2.5 concentration and particles size increase slowly (first stage), small particles are continuously generated and their concentration increases rapidly (second stage), small particles aggregate into more large particles and the growth of concentration slows down (third stage), the PM2.5 concentration and particle aggregation sizes increase rapidly (fourth stage), and (4) the ultrafine particles denoted as "building unit" act as the fundamentals of the aggregated particles. This work has tremendous implications in providing measures for controlling the particle emissions from 3D printing, which would facilitate the extensive application of 3D printing. In addition, this study provides a potential application scenario for nanofiber-based air filters other than laboratory theoretical investigation.

Fume emissions from a low-cost 3-D printer with various filaments

3-D printing is an additive manufacturing process involving the injection of melted thermoplastic polymers, which are then laid down in layers to achieve a pre-designed shape. The heated deposition process raises concerns of potential aerosol and volatile organic compounds (VOC) emission and exposure. The decreasing cost of desktop 3-D printers has made the use of 3-D printers more acceptable in non-industrial workplaces lacking sufficient ventilation. Meanwhile, little is known about the characteristics of 3-D printing fume emission. The objective of this study was to characterize aerosols and VOC emissions generated from various filaments used with a low-cost 3-D printer in an environmental testing chamber. A pre-designed object was printed in 1.25 hours using eight types of filaments. A scanning mobility particle sizer and an aerodynamic particle sizer were employed to measure the particle size distribution in sub-half-micron fraction (<0.5 µm) and super-half-micron fraction (0.5-20 µm), respectively. VOC concentration was monitored real-time by a photoionization detector and sampled with a tri-sorbent thermal desorption tube, and analyzed by thermal desorption gas chromatography mass spectrometry (TD-GC/MS). Results showed high levels of fume particles emission rate (1.0 × 10⁷ to 1.2 × 10¹⁰ #/min) in the sub-half-micron range with mode sizes of 41-83 nm. Particle concentrations peaked during the heat-up and solid layer printing periods. Total VOC concentration in the chamber followed a first-order buildup, with predominant VOC species in the chamber were breakdown and reaction products of the filaments, such as styrene from ABS filaments. These findings and exposure scenario estimation suggest that although the VOC concentrations were much lower than occupational exposure limits, particles with size less than micron might be a concern for users of low-cost 3-D printers due to high respirablity, especially if used in settings without proper guidance and engineering control.

Characterization of chemical contaminants generated by a desktop fused deposition modeling 3-dimensional Printer

Printing devices are known to emit chemicals into the indoor atmosphere. Understanding factors that influence release of chemical contaminants from printers is necessary to develop effective exposure assessment and control strategies. In this study, a desktop fused deposition modeling (FDM) 3-dimensional (3-D) printer using acrylonitrile butadiene styrene (ABS) or polylactic acid (PLA) filaments and two monochrome laser printers were evaluated in a 0.5 m3 chamber. During printing, chamber air was monitored for vapors using a real-time photoionization detector (results expressed as isobutylene equivalents) to measure total volatile organic compound (TVOC) concentrations, evacuated canisters to identify specific VOCs by off-line gas chromatography-mass spectrometry (GC-MS) analysis, and liquid bubblers to identify carbonyl compounds by GC-MS. Airborne particles were collected on filters for off-line analysis using scanning electron microscopy with an energy dispersive x-ray detector to identify elemental constituents. For 3-D printing, TVOC emission rates were influenced by a printer malfunction, filament type, and to a lesser extent, by filament color; however, rates were not influenced by the number of printer nozzles used or the manufacturer's provided cover. TVOC emission rates were significantly lower for the 3-D printer (49-3552 µg h-1) compared to the laser printers (5782-7735 µg h-1). A total of 14 VOCs were identified during 3-D printing that were not present during laser printing. 3-D printed objects continued to off-gas styrene, indicating potential for continued exposure after the print job is completed. Carbonyl reaction products were likely formed from emissions of the 3-D printer, including 4-oxopentanal. Ultrafine particles generated by the 3-D printer using ABS and a laser printer contained chromium. Consideration of the factors that influenced the release of chemical contaminants (including known and suspected asthmagens such as styrene and 4-oxopentanal) from a FDM 3-D printer should be made when designing exposure assessment and control strategies.

Is 3D printing safe? Analysis of the thermal treatment of thermoplastics: ABS, PLA, PET, and nylon

The fast development of low-cost desktop three-dimensional (3D) printers has made those devices widely accessible for goods manufacturing at home. However, is it safe? Users may belittle the effects or influences of pollutants (organic compounds and ultrafine particles) generated by the devices in question. Within the scope of this study, the authors attempt to investigate thermal decomposition of the following commonly used, commercially available thermoplastic filaments: acrylonitrile-butadiene-styrene (ABS), polylactic acid (PLA), polyethylene terephthalate (PET), and nylon. Thermogravimetric analysis has shown the detailed thermal patterns of their behavior upon increasing temperature in neutral atmosphere, while GC analysis of organic vapors emitted during the process of heating thermoplastics have made it possible to obtain crucial pieces of information about the toxicity of 3D printing process. The conducted study has shown that ABS is significantly more toxic than PLA. The emission of volatile organic compounds (VOC) has been in the range of 0.50 µmol/h. Styrene has accounted for more than 30% of total VOC emitted from ABS, while for PLA, methyl methacrylate has been detected as the predominant compound (44% of total VOCs emission). Moreover, the authors have summarized available or applicable methods that can eliminate formed pollutants and protect the users of 3D printers. This article summarizes theoretical knowledge on thermal degradation of polymers used for 3D printers and shows results of authors' investigation, as well as presents forward-looking solutions that may increase the safety of utilization of 3D printers.

Airborne particle emission of a commercial 3D printer: the effect of filament material and printing temperature

The knowledge of exposure to the airborne particle emitted from three-dimensional (3D) printing activities is becoming a crucial issue due to the relevant spreading of such devices in recent years. To this end, a low-cost desktop 3D printer based on fused deposition modeling (FDM) principle was used. Particle number, alveolar-deposited surface area, and mass concentrations were measured continuously during printing processes to evaluate particle emission rates (ERs) and factors. Particle number distribution measurements were also performed to characterize the size of the emitted particles. Ten different materials and different extrusion temperatures were considered in the survey. Results showed that all the investigated materials emit particles in the ultrafine range (with a mode in the 10-30-nm range), whereas no emission of super-micron particles was detected for all the materials under investigation. The emission was affected strongly by the extrusion temperature. In fact, the ERs increase as the extrusion temperature increases. Emission rates up to 1×10¹²  particles min^-1 were calculated. Such high ERs were estimated to cause large alveolar surface area dose in workers when 3D activities run. In fact, a 40-min-long 3D printing was found to cause doses up to 200 mm² .

A new chapter in pharmaceutical manufacturing: 3D-printed drug products

FDA recently approved a 3D-printed drug product in August 2015, which is indicative of a new chapter for pharmaceutical manufacturing. This review article summarizes progress with 3D printed drug products and discusses process development for solid oral dosage forms. 3D printing is a layer-by-layer process capable of producing 3D drug products from digital designs. Traditional pharmaceutical processes, such as tablet compression, have been used for decades with established regulatory pathways. These processes are well understood, but antiquated in terms of process capability and manufacturing flexibility. 3D printing, as a platform technology, has competitive advantages for complex products, personalized products, and products made on-demand. These advantages create opportunities for improving the safety, efficacy, and accessibility of medicines. Although 3D printing differs from traditional manufacturing processes for solid oral dosage forms, risk-based process development is feasible. This review highlights how product and process understanding can facilitate the development of a control strategy for different 3D printing methods. Overall, the authors believe that the recent approval of a 3D printed drug product will stimulate continual innovation in pharmaceutical manufacturing technology. FDA encourages the development of advanced manufacturing technologies, including 3D-printing, using science- and risk-based approaches.

Emissions of Ultrafine Particles and Volatile Organic Compounds from Commercially Available Desktop Three-Dimensional Printers with Multiple Filaments

Previous research has shown that desktop 3D printers can emit large numbers of ultrafine particles (UFPs, particles less than 100 nm) and some hazardous volatile organic compounds (VOCs) during printing, although very few filament and 3D printer combinations have been tested to date. Here we quantify emissions of UFPs and speciated VOCs from five commercially available filament extrusion desktop 3D printers utilizing up to nine different filaments by controlled experiments in a test chamber. Median estimates of time-varying UFP emission rates ranged from ∼10(8) to ∼10(11) min(-1) across all tested combinations, varying primarily by filament material and, to a lesser extent, bed temperature. The individual VOCs emitted in the largest quantities included caprolactam from nylon-based and imitation wood and brick filaments (ranging from ∼2 to ∼180 μg/min), styrene from acrylonitrile butadiene styrene (ABS) and high-impact polystyrene (HIPS) filaments (ranging from ∼10 to ∼110 μg/min), and lactide from polylactic acid (PLA) filaments (ranging from ∼4 to ∼5 μg/min). Results from a screening analysis of potential exposure to these products in a typical small office environment suggest caution should be used when operating many of the printer and filament combinations in poorly ventilated spaces or without the aid of combined gas and particle filtration systems.

Emission of particulate matter from a desktop three-dimensional (3D) printer

Desktop three-dimensional (3D) printers are becoming commonplace in business offices, public libraries, university labs and classrooms, and even private homes; however, these settings are generally not designed for exposure control. Prior experience with a variety of office equipment devices such as laser printers that emit ultrafine particles (UFP) suggests the need to characterize 3D printer emissions to enable reliable risk assessment. The aim of this study was to examine factors that influence particulate emissions from 3D printers and characterize their physical properties to inform risk assessment. Emissions were evaluated in a 0.5-m(3) chamber and in a small room (32.7 m(3)) using real-time instrumentation to measure particle number, size distribution, mass, and surface area. Factors evaluated included filament composition and color, as well as the manufacturer-provided printer emissions control technologies while printing an object. Filament type significantly influenced emissions, with acrylonitrile butadiene styrene (ABS) emitting larger particles than polylactic acid (PLA), which may have been the result of agglomeration. Geometric mean particle sizes and total particle (TP) number and mass emissions differed significantly among colors of a given filament type. Use of a cover on the printer reduced TP emissions by a factor of 2. Lung deposition calculations indicated a threefold higher PLA particle deposition in alveoli compared to ABS. Desktop 3D printers emit high levels of UFP, which are released into indoor environments where adequate ventilation may not be present to control emissions. Emissions in nonindustrial settings need to be reduced through the use of a hierarchy of controls, beginning with device design, followed by engineering controls (ventilation) and administrative controls such as choice of filament composition and color.