Emissions of Nanoparticles and Gaseous Material from 3D Printer Operation

Current trends in 3D printed gastroretentive floating drug delivery systems: A comprehensive review

Gastrointestinal (GI) environment is influenced by several factors (gender, genetics, sex, disease state, food) leading to oral drug absorption variability or to low bioavailability. In this scenario, gastroretentive drug delivery systems (GRDDS) have been developed in order to solve absorption problems, to lead to a more effective local therapy or to allow sustained drug release during a longer time period than the typical oral sustained release dosage forms. Among all GRDDS, floating systems seem to provide a promising and practical approach for achieving a long intra-gastric residence time and sustained release profile. In the last years, a novel technique is being used to manufacture this kind of systems: three-dimensional (3D) printing technology. This technique provides a versatile and easy process to manufacture personalized drug delivery systems. This work presents a systematic review of the main 3D printing based designs proposed up to date to manufacture floating systems. We have also summarized the most important parameters involved in buoyancy and sustained release of the systems, in order to facilitate the scale up of this technology to industrial level. Finally, a section discussing about the influence of materials in drug release, their biocompatibility and safety considerations have been included.

The Quest for the Holy Grail Of 3D Printing: A Critical Review of Recycling in Polymer Powder Bed Fusion Additive Manufacturing

The benefits of additive manufacturing (AM) are widely recognised, boosting the AM method's use in industry, while it is predicted AM will dominate the global manufacturing industry. Alas, 3D printing's growth is hindered by its sustainability. AM methods generate vast amounts of residuals considered as waste, which are disposed of. Additionally, the energy consumed, the materials used, and numerous other factors render AM unsustainable. This paper aims to bring forward all documented solutions in the literature. The spotlight is on potential solutions for the Powder Bed Fusion (PBF) AM, focusing on Selective Laser Sintering (SLS), as these are candidates for mass manufacturing by industry. Solutions are evaluated critically, to identify research gaps regarding the recyclability of residual material. Only then can AM dominate the manufacturing industry, which is extremely important since this is a milestone for our transition into sustainable manufacturing. This transition itself is a complex bottleneck on our quest for becoming a sustainable civilisation. Unlike previous reviews that primarily concentrate on specific AM recycling materials, this paper explores the state of the art in AM recycling processes, incorporating the latest market data and projections. By offering a holistic and forward-looking perspective on the evolution and potential of AM, this review serves as a valuable resource for researchers and industry professionals alike.

3D printer emissions elicit filament-specific and dose-dependent metabolic and genotoxic effects in human airway epithelial cells

Three-dimensional (3D) printers have become popular educational tools in secondary and post-secondary STEM curriculum; however, concerns have emerged regarding inhalation exposures and associated health risks. Current evidence suggests that filament materials and site conditions may cause differences in the chemical profiles and toxicological properties of 3D printer emissions; however, few studies have evaluated exposures directly in the classroom. In this study, we monitored and sampled particulate matter (PM) emitted from acrylonitrile-butadiene-styrene (ABS) and polylactic acid (PLA) filaments during a 3-hour 3D printing session in a high school classroom using aerosol monitoring instrumentation and collection media. To evaluate potential inhalation risks, Multiple Path Particle Dosimetry (MPPD) modeling was used to estimate inhaled doses and calculate in vitro concentrations based on the observed aerosol data and specific lung and breathing characteristics. Dynamic light scattering was used to evaluate the hydrodynamic diameter, zeta potential, and polydispersity index (PDI) of extracted PM emissions dispersed in cell culture media. Small airway epithelial cells (SAEC) were employed to determine cellular viability, genotoxic, inflammatory, and metabolic responses to each emission exposure using MTS, ELISA, and high-performance liquid chromatography-mass spectrometry (HPLC-MS), respectively. Aerosol monitoring data revealed that emissions from ABS and PLA filaments generated similar PM concentrations within the ultrafine and fine ranges. However, DLS analysis showed differences in the physicochemical properties of ABS and PLA PM, where the hydrodynamic diameter of PLA PM was greater than ABS PM, which may have influenced particle deposition rates and cellular outcomes. While exposure to both ABS and PLA PM reduced cell viability and induced MDM2, an indicator of genomic instability, PLA PM alone increased gamma-H2AX, a marker of double-stranded DNA breaks. ABS and PLA emissions also increased the release of pro-inflammatory cytokines, although this did not reach significance. Furthermore, metabolic profiling via high performance liquid chromatography-mass spectrometry (HPLC-MS) and subsequent pathway analysis revealed filament and dose dependent cellular metabolic alterations. Notably, our metabolomic analysis also revealed key metabolites and pathways implicated in PM-induced oxidative stress, DNA damage, and respiratory disease that were perturbed across both tested doses for a given filament. Taken together, these findings suggest that use of ABS and PLA filaments in 3D printers within school settings may potentially contribute to adverse respiratory responses especially in vulnerable populations.

Evaluation of particle and volatile organic compound emissions during the use of 3D pens

This study investigated particle and volatile organic compound (VOC) emission rates (ER) from 3D pens, which are increasingly popular in children's toys. Nine filaments and two 3D pens were evaluated using a flow tunnel, a scanning mobility particle sizer, a proton-transfer-reaction time-of-flight mass spectrometer for particles, and a thermal desorption-gas chromatography-mass spectrometer for VOCs. Results showed that the ERs varied with the pen type, filament, and brand. The particle ER was highest for acrylonitrile butadiene styrene (ABS), followed by polylactic acid (PLA) and polycaprolactone (PCL). Notably, ERs of 83 % and 33 % of ABS and PLA filaments exceeded the maximum allowable particle ER (MAER; 5 × 109 particles/min) for 3D printers but were lower than the VOC MAER (173 μg/min in the office). Different filaments emitted diverse VOCs; ABS emitted styrene and benzene, PLA emitted lactide, and PCL emitted phenol. While particle ERs from 3D pens were comparable to those from printers, the total VOC ERs from 3D pens were slightly lower. Caution is warranted when using 3D pens because of potential health risks, especially their prolonged use, proximity to the breathing zone, and usage by children. This study highlights the need for considering particles and VOCs when assessing the safety of 3D pens, emphasizing awareness of potential hazards, particularly in child-oriented settings.

Application of 3D printing for fabrication of superhydrophobic surfaces with reversible wettability

Control of surface wettability is needed in many applications. The potential use of 3D printing technology to gain control over wettability remains largely unexplored. In this paper, Fused Deposition Molding (FDM) 3D printing technology was utilized to print polylactic acid (PLA) microplate array structures to generate superhydrophobic surfaces with reversable wetting properties. This was achieved by spraying polydimethylsiloxane (PDMS) and silica (SiO2) solutions, over microplate surfaces. Anisotropic wetting properties were also achieved based on the surface structure design. Due to the shape memory properties of PLA, the morphology of the microplate arrays could be switched between the original upright shape and deformed shape. Through alternating pressing and heating treatments, the microplate arrays showed anisotropic wettability switching. The difference between the contact angle (CA) and sliding angle (SA) of water droplets on the original surface parallel to and perpendicular to the microplate array direction were ΔCA = 7° and ΔSA = 3° respectively, and those on the surface of the deformed microplate array were ΔCA = 7° and ΔSA = 21°, respectively. This process enabled reversible alteration in the wetting behavior of water droplets on the original and deformed surfaces between sliding and sticking states. PLA-based shape memory anisotropic superhydrophobic surfaces with tunable adhesion were successfully applied to rewritable platforms, micro droplet reaction platforms, and gas sensing.

Effect of Three-Dimensional-Printed Thermoplastics Used in Sensor Housings on Common Atmospheric Trace Gasses

Low-cost air quality sensors (LCSs) are becoming more ubiquitous as individuals and communities seek to reduce their exposure to poor air quality. Compact, efficient, and aesthetically designed sensor housings that do not interfere with the target air quality measurements are a necessary component of a low-cost sensing system. The selection of appropriate housing material can be an important factor in air quality applications employing LCSs. Three-dimensional printing, specifically fused deposition modeling (FDM), is a standard for prototyping and small-scale custom plastics production because of its low cost and ability for rapid iteration. However, little information exists about whether FDM-printed thermoplastics affect measurements of trace atmospheric gasses. This study investigates how five different FDM-printed thermoplastics (ABS, PETG, PLA, PC, and PVDF) affect the concentration of five common atmospheric trace gasses (CO, CO2, NO, NO2, and VOCs). The laboratory results show that the thermoplastics, except for PVDF, exhibit VOC off-gassing. The results also indicate no to limited interaction between all of the thermoplastics and CO and CO2 and a small interaction between all of the thermoplastics and NO and NO2.

Everything falls apart: How solids degrade and release nanomaterials, composite fragments, and microplastics

To ensure the safe use of materials, one must assess the identity and quantity of exposure. Solid materials, such as plastics, metals, coatings and cements, degrade to some extent during their life cycle, and releases can occur during manufacturing, use and end-of-life. Releases (e.g., what is released, how does release happen, and how much material is released) depend on the composition and internal (nano)structures of the material as well as the applied stresses during the lifecycle. We consider, in some depth, releases from mechanical, weathering and thermal stresses and specifically address the use cases of fused-filament 3D printing, dermal contact, food contact and textile washing. Solid materials can release embedded nanomaterials, composite fragments, or micro- and nanoplastics, as well as volatile organics, ions and dissolved organics. The identity of the release is often a heterogenous mixture and requires adapted strategies for sampling and analysis, with suitable quality control measures. Control materials enhance robustness by enabling comparative testing, but reference materials are not always available as yet. The quantity of releases is typically described by time-dependent rates that are modulated by the nature and intensity of the applied stress, the chemical identity of the polymer or other solid matrix, and the chemical identity and compatibility of embedded engineered nanomaterials (ENMs) or other additives. Standardization of methods and the documentation of metadata, including all the above descriptors of the tested material, applied stresses, sampling and analytics, are identified as important needs to advance the field and to generate robust, comparable assessments. In this regard, there are strong methodological synergies between the study of all solid materials, including the study of micro- and nanoplastics. From an outlook perspective, we review the hazard of the released entities, and show how this informs risk assessment. We also address the transfer of methods to related issues such as tyre wear, advanced materials and advanced manufacturing, biodegradable polymers, and non-solid matrices. As the consideration of released entities will become more routine in industry via lifecycle assessment in Safe-and-Sustainable-by-Design practices, release assessments will require careful design of the study with quality controls, the use of agreed-on test materials and standardized methods where these exist and the adoption of clearly defined data reporting practices that enable data reuse, meta-analyses, and comparative studies.

Investigating environmentally persistent free radicals (EPFRs) emissions of 3D printing process

In recent years, the emission of particles and gaseous pollutants from 3D printing has attracted much attention due to potential health risks. This study investigated the generation of environmentally persistent free radicals (EPFRs, organic free radicals stabilized on or inside particles) in total particulate matter (TPM) released during the 3D printing process. Commercially available 3D printer filaments, made of acrylonitrile-butadiene-styrene (ABS) in two different colors and metal content, ABS-blue (19.66 μg/g Cu) and ABS-black (3.69 μg/g Fe), were used for printing. We hypothesized that the metal content/composition of the filaments contributes not only to the type and number of EPFRs in TPM emissions, but also impacts the overall yield of TPM emissions. TPM emissions during printing with ABS-blue (11.28 μg/g of printed material) were higher than with ABS-black (7.29 μg/g). Electron paramagnetic resonance (EPR) spectroscopy, employed to measure EPFRs in TPM emissions of both filaments, revealed higher EPFR concentrations in ABS-blue TPM (6.23 × 1017 spins/g) than in ABS-black TPM (9.72 × 1016 spins/g). The presence of copper in the ABS-blue contributed to the formation of mostly oxygen-centered EPFR species with a g-factor of ~2.0041 and a lifetime of 98 days. The ABS-black EPFR signal had a lower g-factor of ~2.0011, reflecting the formation of superoxide radicals during the printing process, which were shown to have an "estimated tentative" lifetime of 26 days. Both radical species (EPFRs and superoxides) translate to a potential health risk through inhalation of emitted particles.

Real-Time Exposure to 3D-Printing Emissions Elicits Metabolic and Pro-Inflammatory Responses in Human Airway Epithelial Cells

Three-dimensional (3D) printer usage in household and school settings has raised health concerns regarding chemical and particle emission exposures during operation. Although the composition of 3D printer emissions varies depending on printer settings and materials, little is known about the impact that emissions from different filament types may have on respiratory health and underlying cellular mechanisms. In this study, we used an in vitro exposure chamber system to deliver emissions from two popular 3D-printing filament types, acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA), directly to human small airway epithelial cells (SAEC) cultured in an air-liquid interface during 3D printer operation. Using a scanning mobility particle sizer (SMPS) and an optical particle sizer (OPS), we monitored 3D printer particulate matter (PM) emissions in terms of their particle size distribution, concentrations, and calculated deposited doses. Elemental composition of ABS and PLA emissions was assessed using scanning electron microscopy coupled with energy dispersive X-ray spectroscopy (SEM-EDX). Finally, we compared the effects of emission exposure on cell viability, inflammation, and metabolism in SAEC. Our results reveal that, although ABS filaments emitted a higher total concentration of particles and PLA filaments emitted a higher concentration of smaller particles, SAEC were exposed to similar deposited doses of particles for each filament type. Conversely, ABS and PLA emissions had distinct elemental compositions, which were likely responsible for differential effects on SAEC viability, oxidative stress, release of inflammatory mediators, and changes in cellular metabolism. Specifically, while ABS- and PLA-emitted particles both reduced cellular viability and total glutathione levels in SAEC, ABS emissions had a significantly greater effect on glutathione relative to PLA emissions. Additionally, pro-inflammatory cytokines including IL-1β, MMP-9, and RANTES were significantly increased due to ABS emissions exposure. While IL-6 and IL-8 were stimulated in both exposure scenarios, VEGF was exclusively increased due to PLA emissions exposures. Notably, ABS emissions induced metabolic perturbation on amino acids and energy metabolism, as well as redox-regulated pathways including arginine, methionine, cysteine, and vitamin B3 metabolism, whereas PLA emissions exposures caused fatty acid and carnitine dysregulation. Taken together, these results advance our mechanistic understanding of 3D-printer-emissions-induced respiratory toxicity and highlight the role that filament emission properties may play in mediating different respiratory outcomes.

Polymer Composites in 3D/4D Printing: Materials, Advances, and Prospects

Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionized the manufacturing landscape by enabling the intricate layer-by-layer construction of three-dimensional objects. In contrast to traditional methods relying on molds and tools, AM provides the flexibility to fabricate diverse components directly from digital models without the need for physical alterations to machinery. Four-dimensional printing is a revolutionary extension of 3D printing that introduces the dimension of time, enabling dynamic transformations in printed structures over predetermined periods. This comprehensive review focuses on polymeric materials in 3D printing, exploring their versatile processing capabilities, environmental adaptability, and applications across thermoplastics, thermosetting materials, elastomers, polymer composites, shape memory polymers (SMPs), including liquid crystal elastomer (LCE), and self-healing polymers for 4D printing. This review also examines recent advancements in microvascular and encapsulation self-healing mechanisms, explores the potential of supramolecular polymers, and highlights the latest progress in hybrid printing using polymer-metal and polymer-ceramic composites. Finally, this paper offers insights into potential challenges faced in the additive manufacturing of polymer composites and suggests avenues for future research in this dynamic and rapidly evolving field.

Dermal and oral exposure risks to heavy metals from 3D printing metal-fill thermoplastics

Manufacturing advancements in polymer printing now allow for the addition of metal additives to thermoplastic feedstock up to 80-90 % by weight and subsequent printing on low-cost desktop 3D printers. Particles associated with metal additives are not chemically bound to the plastic polymer, meaning these particles can potentially migrate and become bioavailable. This study investigated the degree to which two human exposure pathways, oral (ingestion) and dermal (skin contact), are important exposure pathways for metals (copper, chromium, and tin) from metal-fill thermoplastics used in consumer fused filament fabrication (FFF). We found that dermal exposure to copper and bronze filaments presents the highest exposure risk due to chloride (Cl-) in synthetic sweat driving copper (Cu2+) release and dissolution. Chromium and tin were released as micron-sized particles < 24 μm in diameter with low bioaccessibility during simulated oral and dermal exposure scenarios, with potential to undergo dissolution in the gastrointestinal tract based on testing using synthetic stomach fluids. The rate of metal particle release increased by one to two orders of magnitude when thermoplastics were degraded under 1 year of simulated UV weathering. This calls into question the long-term suitability of biodegradable polymers such as PLA for use in metal-fill thermoplastics if they are designed not to be sintered. The greatest exposure risk appears to be from the raw filaments rather than the printed forms, with the former having higher metal release rates in water and synthetic body fluids for all but one filament type. For brittle feedstock that requires greater handling, as metal-fill thermoplastics can be, practices common in metal powder 3D printing such as wearing gloves and washing hands may adequately reduce metal exposure risks.

Exposure hazards of particles and volatile organic compounds emitted from material extrusion 3D printing: Consolidation of chamber study data

Ultrafine particles and volatile organic compounds (VOCs) have been detected from material extrusion 3D printing, which is widely used in non-industrial environments. This study consolidates data of 447 particle emission and 58 VOC emission evaluations from a chamber study using a standardized testing method with various 3D printing scenarios. The interquartile ranges of the observed emission rates were 109-1011 #/h for particles and 0.2-1.0 mg/h for total VOC. Print material contributed largely to the variations of particle and total VOC emissions and determined the most abundantly emitted VOCs. Printing conditions and filament specifications, included printer brand, print temperature and speed, build plate heating setup, filament brand, color and composite, also affected emissions and resulted in large variations observed in emission profiles. Multiple regression showed that particle emissions were more impacted by various print conditions than VOC emissions. According to indoor exposure modeling, personal and residential exposure scenarios were more likely to result in high exposure levels, often exceeding recommended exposure limits. Hazardous VOCs commonly emitted from 3D printing included aromatics, aldehydes, alcohols, ketones, esters and siloxanes, among which were various carcinogens, irritants and developmental and reproductive toxins. Therefore, 3D printing emits a complex mixture of ultrafine particles and various hazardous chemicals, exposure to which may exceed recommended exposure limits and potentially induce acute, chronic, or developmental health effects for users depending on exposure scenarios.

Inhalation of polycarbonate emissions generated during 3D printing processes affects neuroendocrine function in male rats

Three-dimensional (3D) printing of manufactured goods has increased in the last 10 years. The increased use of this technology has resulted in questions regarding the influence of inhaling emissions generated during printing. The goal of this study was to determine if inhalation of particulate and/or toxic chemicals generated during printing with polycarbonate (PC) plastic affected the neuroendocrine system. Male rats were exposed to 3D-printer emissions (592 µg particulate/m3 air) or filtered air for 4 h/day (d), 4 days/week and total exposures lengths were 1, 4, 8, 15 or 30 days. The effects of these exposures on hormone concentrations, and markers of function and/or injury in the olfactory bulb, hypothalamus and testes were measured after 1, 8 and 30 days exposure. Thirty days of exposure to 3D printer emissions resulted in reductions in thyroid stimulating hormone, follicle stimulating hormone and prolactin. These changes were accompanied by (1) elevation in markers of cell injury; (2) reductions in active mitochondria in the olfactory bulb, diminished gonadotropin releasing hormone cells and fibers as well as less tyrosine hydroxylase immunolabeled fibers in the arcuate nucleus; and (3) decrease in spermatogonium. Polycarbonate plastics may contain bisphenol A, and the effects of exposure to these 3D printer-generated emissions on neuroendocrine function are similar to those noted following exposure to bisphenol A.

Accurate measurements of particle emissions from a three-dimensional printer using a chamber test with a mixer-installed sampling system

Recently, three-dimensional (3D) printing has attracted attention as a new manufacturing technology. However, there is lack of data and regulations regarding the emissions of ultrafine particles from 3D printers. Therefore, we investigated particle emissions from a 3D printer using a chamber system. The test system was improved by installing a developed mixer for accurate measurement. Without a mixer, the particle concentration was unstable depending on the sampling point; however, reliable data with good uniformity were obtained by installing a mixer. Using the test system with a mixer, we investigated particle emissions from a 3D printer during operation. Filaments made each of acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) were used as the printing material. The effects of nozzle temperature and printing time were investigated. Compared to the effect of the printing time, the nozzle temperature had greater impact on the particle emissions. The dominant particle size for the emissions from a 3D printer is less than 10 nm, and the particle concentration decreased with increasing particle size.

Metal compositions of particle emissions from material extrusion 3D printing: Emission sources and indoor exposure modeling

Material extrusion 3D printing has been widely used in industrial, educational and residential environments, while its exposure health impacts have not been well understood. High levels of ultrafine particles are found being emitted from 3D printing and could pose a hazard when inhaled. However, metals that potentially transfer from filament additives to emitted particles could also add to the exposure hazard, which have not been well characterized for their emissions. This study analyzed metal (and metalloid) compositions of raw filaments and in the emitted particles during printing; studied filaments included pure polymer filaments with metal additives and composite filaments with and without metal powder. Our chamber study found that crustal metals tended to have higher partitioning factors from filaments to emitted particles; silicon was the most abundant element in emitted particles and had the highest yield per filament mass. However, bronze and stainless-steel powder added in composite filaments were less likely to transfer from filament to particle. For some cases, boron, arsenic, manganese, and lead were only detected in particles, which indicated external sources, such as the printers themselves. Heavy metals with health concerns were also detected in emitted particles, while their estimated exposure concentrations in indoor air were below air quality standards and occupational regulations. However, total particle exposure concentrations estimated for indoor environments could exceed ambient air fine particulate standards.

Evaluation of formaldehyde, particulate matters 2.5 and 10 emitted to a 3D printing workspace based on ventilation

Recently, the development of 3D printing (3DP) technology and its application in various fields have improved our quality of life. However, hazardous materials that affect the human body, such as formaldehyde and particulate matter (PM), are emitted into the air during 3DP. This study measured the formaldehyde, PM₁₀, and PM_2.5 emitted by 3DP with the ventilation operation using six materials in material extrusion (ME) and vat photopolymerization (VP) and compared them between the 3DP workspace and the control setting with test-retest validation by two researchers. The experiments were divided into four stages based on the 3DP and ventilation operation. A linear mixed model was used to analyze the mean differences and tendencies between the 3DP workspace and the control setting. The change as ventilation was switched from off to on was evaluated by calculating the area. The differences and tendencies were shown in the statistically significant differences from a post-hoc test (α = 0.0125) except for some cases. There was a significant difference in formaldehyde depending on the ventilation operation; however, only a minor difference in PM_10, and PM_2.5 was confirmed. The amount of formaldehyde exceeding the standard was measured in all materials during 3DP without ventilation. Therefore, it is recommended to operate ventilation systems.

TVOC - Revisited

BACKGROUND

TVOC (total volatile organic compounds) has been used as a sum parameter in indoor air sciences for over 40 years. In the beginning, individual VOC concentrations determined by gas chromatography were simply added together. However, several methods for calculating TVOC have become established over time.

METHODS

To understand the manifold definitions of TVOC, one must trace the history of indoor air sciences and analytical chemistry. Therefore, in this work, the original approaches of TVOC are searched and explained. A detailed description of the measurement methods is followed by a critical evaluation of the various TVOC values and their possible applications. The aim is to give the reader a deeper understanding of TVOC in order to use this parameter correctly and to be able to better assess published results. In addition, related sum values such as TSVOC and TVVOC are also addressed.

RESULTS

A milestone was the analytical definition of VOCs and TVOC in 1997. A list of VOCs that should at least be considered when calculating TVOC was also provided. This list represented the status at that time, is no longer up-to-date and is being updated by a European working group as part of a harmonization process. However, there is still confusion about the exact definition and reasonable application of TVOC. The signals of other sum parameters, measured with photoacoustics, flame ionization, photoionization or electrochemical sensors, are also often given under the term TVOC.

CONCLUSIONS

It was recognized early that TVOC is not a toxicologically based parameter and is therefore only suitable for a limited number of screening purposes. Consequently, TVOC cannot be used in connection with health-related and odor-related issues. Nevertheless, such references are repeatedly made, which has led to controversial scientific discussions and even court decisions in Germany about the correct and improper use of TVOC.

Volatile organic compound and particulate emissions from the production and use of thermoplastic biocomposite 3D printing filaments

Biocomposites (BCs) can be used as substitutes for unsustainable polymers in 3D printing, but their safety demands additional investigation as biological fillers may produce altered emissions during thermal processing. Commercial filament extruders can be used to produce custom feedstocks, but they are another source of airborne contaminants and demand further research. These knowledge gaps are targeted in this study. Volatile organic compound (VOC), carbonyl compound, ultrafine particle (UFP), and fine (PM_2.5) and coarse (PM₁₀) particle air concentrations were measured in this study as a filament extruder and a 3D printer were operated under an office environment using one PLA and four PLA-based BC feedstocks. Estimates of emission rates (ERs) for total VOCs (TVOC) and UFPs were also calculated. VOCs were analyzed with a GC-MS system, carbonyls were analyzed with an LC-MS/MS system, whereas real-time particle concentrations were monitored with continuously operating instruments. VOC concentrations were low throughout the experiment; TVOC ranged between 34-63 µg/m³ during filament extrusion and 41-56 µg/m³ during 3D printing, which represent calculated TVOC ERs of 2.6‒3.6 × 10² and 2.9‒3.6 × 10² µg/min. Corresponding cumulative carbonyls ranged between 60-91 and 190-253 µg/m³. Lactide and miscellaneous acids and alcohols were the dominant VOCs, while acetone, 2-butanone, and formaldehyde were the dominant carbonyls. Terpenes contributed for ca. 20-40% of TVOC during BC processing. The average UFP levels produced by the filament extruder were 0.85 × 10²-1.05 × 10³ #/cm³, while the 3D printer generated 6.05 × 10²-2.09 × 10³ #/cm³ particle levels. Corresponding particle ERs were 5.3 × 10⁸-6.6 × 10⁹ and 3.8 × 10⁹-1.3 × 10¹⁰ #/min. PM_2.5 and PM₁₀ particles were produced in the following average quantities; PM_2.5 levels ranged between 0.2-2.2 µg/m³, while PM₁₀ levels were between 5-20 µg/m³ for all materials. The main difference between the pure PLA and BC feedstock emissions was terpenes, present during all BC extrusion processes. BCs are similar emission sources as pure plastics based on our findings, and a filament extruder produces contaminants at comparable or slightly lower levels in comparison to 3D printers.

Nanomaterial-Embedded DNA Films on 2D Frames

Recently, 3D printing has provided opportunities for designing complex structures with ease. These printed structures can serve as molds for complex materials such as DNA and cetyltrimethylammonium chloride (CTMA)-modified DNA that have easily tunable functionalities via the embedding of various nanomaterials such as ions, nanoparticles, fluorophores, and proteins. Herein, we develop a simple and efficient method for constructing DNA flat and curved films containing water-soluble/thermochromatic dyes and di/trivalent ions and CTMA-modified DNA films embedded with organic light-emitting molecules (OLEM) with the aid of 2D/3D frames made by a 3D printer. We study the Raman spectra, current, and resistance of Cu²⁺-doped and Tb³⁺-doped DNA films and the photoluminescence of OLEM-embedded CTMA-modified DNA films to better understand the optoelectric characteristics of the samples. Compared to pristine DNA, ion-doped DNA films show noticeable variation of Raman peak intensities, which might be due to the interaction between the ion and phosphate backbone of DNA and the intercalation of ions in DNA base pairs. As expected, ion-doped DNA films show an increase of current with an increase in bias voltage. Because of the presence of metallic ions, DNA films with embedded ions showed relatively larger current than pristine DNA. The photoluminescent emission peaks of CTMA-modified DNA films with OLEM_Red, OLEM_Green, and OLEM_Blue were obtained at the wavelengths of 610, 515, and 469 nm, respectively. Finally, CIE color coordinates produced from CTMA-modified DNA films with different OLEM color types were plotted in color space. It may be feasible to produce multilayered DNA films as well. If so, multilayered DNA films embedded with different color dyes, ions, fluorescent materials, nanoparticles, proteins, and drug molecules could be used to realize multifunctional physical devices such as energy harvesting and chemo-bio sensors in the near future.

Human exposure to metals in consumer-focused fused filament fabrication (FFF)/ 3D printing processes

Fused filament fabrication (FFF) or 3D printing is a growing technology used in industry, cottage industry and for consumer applications. Low-cost 3D printing devices have become increasingly popular among children and teens. Consequently, 3D printers are increasingly common in households, schools, and libraries. Because the operation of 3D printers is associated with the release of inhalable particles and volatile organic compounds (VOCs), there are concerns of possible health implications, particularly for use in schools and residential environments that may not have adequate ventilation such as classrooms bedrooms and garages, etc. Along with the growing consumer market for low-cost printers and printer pens, there is also an expanding market for a range of specialty filaments with additives such as inorganic colorants, metal particles and nanomaterials as well as metal-containing flame retardants, antioxidants, heat stabilizers and catalysts. Inhalation of particulate-associated metals may represent a health risk depending on both the metal and internal dose to the respiratory tract. Little has been reported, however, about the presence, speciation, and source of metals in the emissions; or likewise the effect of metals on emission processes and toxicological implications of these 3D printer generated emissions. This report evaluates various issues including the following: metals in feedstock with a focus on filament characteristics and function of metals; the effect of metals on the emissions and metals detected in emissions; printer emissions, particle formation, transport, and transformation; exposure and translation to internal dose; and potential toxicity on inhaled dose. Finally, data gaps and potential areas of future research are discussed within these contexts.

Facilitating Safe FFF 3D Printing: A Prototype Material Case Study

Three-dimensional (3D) printing has introduced a paradigm shift in the manufacturing world, and it is increasing in popularity. In cases of such rapid and widespread acceptance of novel technologies, material or process safety issues may be underestimated, due to safety research being outpaced by the breakthroughs of innovation. However, a definitive approach in studying the various occupational or environmental risks of new technologies is a vital part of their sustainable application. In fused filament fabrication (FFF) 3D printing, the practicality and simplicity of the method are juxtaposed by ultrafine particle (UFP) and volatile organic compound (VOC) emission hazards. In this work, the decision of selecting the optimal material for the mass production of a microfluidic device substrate via FFF 3D printing is supported by an emission/exposure assessment. Three candidate prototype materials are evaluated in terms of their comparative emission potential. The impact of nozzle temperature settings, as well as the microfluidic device’s structural characteristics regarding the magnitude of emissions, is evaluated. The projected exposure of the employees operating the 3D printer is determined. The concept behind this series of experiments is proposed as a methodology to generate an additional set of decision-support decision-making criteria for FFF 3D printing production cases.

Systematic ranking of filaments regarding their particulate emissions during fused filament fabrication 3D printing by means of a proposed standard test method

The diversity of fused filament fabrication (FFF) filaments continues to grow rapidly as the popularity of FFF-3D desktop printers for the use as home fabrication devices has been greatly increased in the past decade. Potential harmful emissions and associated health risks when operating indoors have induced many emission studies. However, the lack of standardization of measurements impeded an objectifiable comparison of research findings. Therefore, we designed a chamber-based standard method, i.e., the strand printing method (SPM), which provides a standardized printing procedure and quantifies systematically the particle emission released from individual FFF-3D filaments under controlled conditions. Forty-four marketable filament products were tested. The total number of emitted particles (TP) varied by approximately four orders of magnitude (10⁹  ≤ TP ≤ 10¹³ ), indicating that origin of polymers, manufacturer-specific additives, and undeclared impurities have a strong influence. Our results suggest that TP characterizes an individual filament product and particle emissions cannot be categorized by the polymer type (e.g., PLA or ABS) alone. The user's choice of a filament product is therefore decisive for the exposure to released particles during operation. Thus, choosing a filament product awarded for low emissions seems to be an easily achievable preemptive measure to prevent health hazards.

Assessment and Mitigation of Exposure of 3-D Printer Emissions

This study monitored particulates, and volatile organic compounds (VOCs) emitted from 3-D printers using acrylonitrile-butadiene-styrene copolymer (ABS) filaments at a workplace to assess exposure before and after introducing exposure mitigation measures. Air samples were collected in the printing room and adjacent corridor, and real-time measurements of ultrafine and fine particle were also conducted. Extensive physicochemical characterizations of 3-D printer emissions were performed, including real-time (size distribution, number concentration) nanoparticle characterization, size-fractionated mass distribution and concentration, as well as chemical composition for metals by ICP-MS and VOCs by GC-FID, real-time VOC monitors, and proton-transfer-reaction time-of-flight mass spectrometer (PTR-TOF-MS). Air sampling showed low levels of total suspended particulates (TSP, 9–12.5/m³), minimal levels (1.93–4 ppm) of total volatile organic chemicals (TVOC), and formaldehyde (2.5–21.7 ppb). Various harmful gases, such as formaldehyde, acrolein, acetone, hexane, styrene, toluene, and trimethylamine, were detected at concentrations in the 1–100 ppb by PTR-TOF-MS when air sample was collected into the Tedlar bag from the front of the 3-D printer. Ultrafine particles having an average particle size (30 nm count median diameter and 71 nm mass median diameter) increased during the 3-D printing operation. They decreased to the background level after the 3-D printing operation, while fine particles continually increased after the termination of 3-D printing to the next day morning. The exposure to 3-D printer emissions was greatly reduced after isolating 3-D printers in the enclosed space. Particle number concentration measured by real-time particle counters (DMAS and OPC) were greatly reduced after isolating 3-D printers to the isolated place.

Real-time monitoring of the emission of volatile organic compounds from polylactide 3D printing filaments

Establishing the emission profile of volatile organic compounds generated during fused deposition modeling 3D printing using polymer filaments is important in terms of both understanding the processes taking place during thermal degradation of thermoplastics, and assessing the user's exposure to potentially harmful volatiles. However, obtaining detailed, real-time qualitative and quantitative results poses a challenge. In this paper solid-phase microextraction-gas chromatography-time-of-flight mass spectrometry and proton transfer reaction time-of-flight mass spectrometry were used to identify and monitor the emission of volatiles during thermal degradation of polylactide filaments and during 3D printing. Filaments of two different grades and three colours were used. It was possible to obtain detailed, time- and temperature-resolved emission profiles of the main products of thermal decomposition of lactide and polylactide 3D printing filaments at concentration levels of a few μg/g. This revealed different temperature-dependent emission characteristics of particular volatiles, such as, among others, lactide, acetaldehyde, acetic acid, and 2-butanone between various polylactide 3D printing filaments. This approach can be used to monitor the emission associated with printing with various other types of polymer 3D printing materials.

Characteristics of ultrafine particles emitted from 3D-pens and effect of partition on children's exposure during 3D-pen operation

A three-dimensional (3D) printing pen is a popular writing instrument that uses a heated nozzle, and is similar to a 3D-printer. Processing thermoplastic filaments with a 3D-pen can emit ultrafine particles (UFPs). 3D-pen education sessions were held with "∏"-shaped partitions for the prevention of coronavirus disease (COVID-19). This study aimed to characterize UFP emissions from two types of 3D-pens and evaluate the influence of "∏"-shaped partitions on UFP exposure. Measurements of UFP emission rates and the size distribution of particles emitted from 3D-pens were conducted in a chamber (2.5 m³ ). The partition's influence on UFP exposure was evaluated with and without a "∏"-shaped partition on a desk. A scanning mobility particle sizer (SMPS) and an optical particle spectrometer (OPS) were used to measure the particle number concentration (PNC) and size distribution. For both 3D-pen A and B, the average emission rates were statistically significantly highest for acrylonitrile butadiene styrene (ABS) filament (8.4 × 10⁶ [3.4] particles/min and 1.1 × 10⁶ [1.8] particles/min), followed by polylactic acid (PLA) (2.8 × 10⁵ [1.5] particles/min and 4.8 × 10⁴ [1.8] particles/min) and polycaprolactone (PCL) filaments (1.4 × 10⁴ [2.8] particles/min and 2.0 × 10⁴ [2.8] particles/min). For all filaments, particles in the Aitken mode (30-100 nm) accounted for the highest proportion. In 3D-pen A, PNCs were higher with the partition than without it for ABS (1.2 × 10⁶ [1.15] particles/cm³ vs. 1.4 × 10⁵ [1.29] particles/cm³ ) and PLA (6.2 × 10⁵ [1.38] particles/cm³ vs. 8.9 × 10⁴ [1.12] particles/cm³ ), whereas for 3D-pen B, they were higher with the partition for ABS (9.6 × 10⁵ [1.13] particles/cm³ vs. 4.9 × 10⁵ [1.22] particles/cm³ ) only. With the partition installed, PNCs decreased to the background level after the operation ended, whereas it took 2-6 min without the partition. However, the mass concentrations of PLA and PCL with 3D-pen A were not statistically significantly different with respect to the partition status. The use of 3D-pens with a partition can lead to high UFP exposure. Therefore, guidelines are required for the safe use of 3D-pens and partitions.

U.S. Federal Agency interests and key considerations for new approach methodologies for nanomaterials

Engineered nanomaterials (ENMs) come in a wide array of shapes, sizes, surface coatings, and compositions, and often possess novel or enhanced properties compared to larger sized particles of the same elemental composition. To ensure the safe commercialization of products containing ENMs, it is important to thoroughly understand their potential risks. Given that ENMs can be created in an almost infinite number of variations, it is not feasible to conduct in vivo testing on each type of ENM. Instead, new approach methodologies (NAMs) such as in vitro or in chemico test methods may be needed, given their capacity for higher throughput testing, lower cost, and ability to provide information on toxicological mechanisms. However, the different behaviors of ENMs compared to dissolved chemicals may challenge safety testing of ENMs using NAMs. In this study, member agencies within the Interagency Coordinating Committee on the Validation of Alternative Methods were queried about what types of ENMs are of agency interest and whether there is agency-specific guidance for ENM toxicity testing. To support the ability of NAMs to provide robust results in ENM testing, two key issues in the usage of NAMs, namely dosimetry and interference/bias controls, are thoroughly discussed.

Parameters Influencing the Emission of Ultrafine Particles during 3D Printing

This paper presents a complex and extensive experimental evaluation of fine particle emissions released by an FDM 3D printer for four of the most common printing materials (ABS, PLA, PET-G, and TPU). These thermoplastic filaments were examined at three printing temperatures within their recommended range. In addition, these measurements were extended using various types of printing nozzles, which influenced the emissions considerably. This research is based on more than a hundred individual measurements for which a standardized printing method was developed. The study presents information about differences between particular printing conditions in terms of the amount of fine particles emitted as well as the particle size distributions during printing periods. This expands existing knowledge about the emission of ultrafine particles during 3D printing, and it can help reduce the emissions of these devices to achieve cleaner and safer 3D printer operations.

State of the art in additive manufacturing and its possible chemical and particle hazards-review

Additive manufacturing, enabling rapid prototyping and so-called on-demand production, has become a common method of creating parts or whole devices. On a 3D printer, real objects are produced layer by layer, thus creating extraordinary possibilities as to the number of applications for this type of devices. The opportunities offered by this technique seem to be pushing new boundaries when it comes to both the use of 3D printing in practice and new materials from which the 3D objects can be printed. However, the question arises whether, at the same time, this solution is safe enough to be used without limitations, wherever and by everyone. According to the scientific reports, three-dimensional printing can pose a threat to the user, not only in terms of physical or mechanical hazards, but also through the potential emissions of chemical substances and fine particles. Thus, the presented publication collects information on the additive manufacturing, different techniques, and ways of printing with application of diverse raw materials. It presents an overview of the last 5 years' publications focusing on 3D printing, especially regarding the potential chemical and particle emission resulting from the use of such printers in both the working environment and private spaces.

The impact of thermal reprocessing of 3D printable polymers on their mechanical performance and airborne pollutant profiles

The alterations in volatile organic compound (VOC) and ultrafine particulate (UFP) matter emission profiles following thermal reprocessing of multiple materials were examined. Additionally, mechanical performance of the materials was studied. The VOCs were identified by collecting air samples with Tenax® TA tubes and analyzing them with a GC–MS system. UFP concentrations were monitored with a portable ultrafine particle counter. Total VOC emissions of all materials were reduced by 28–68% after 5 thermal cycles (TCs). However, slight accumulation of 1,4-dioxane was observed with poly(lactic acid) materials. UFP emissions were reduced by 45–88% for 3D printing grade materials over 5 TCs but increased by 62% in the case of a waste plastic material over 3 TCs. The mechanical performance of the materials was investigated by measuring their tensile strengths (TSs) and elastic moduli (EM) with an axial-torsion testing system. The reprocessed materials expressed fluctuations in their 3D printing qualities and mechanical performances. The mechanical performances were observed to reduce only slightly after 5 TCs, and the trend was observable only after the data was mass-normalized. The TSs of the samples were reduced by 10–24%, while the EM were reduced by 1–9% after 5 TCs. The TS and EM of one material were increased by 14 and 33%, respectively. In conclusion, recycled polymers are plausible 3D printing feedstock alternatives as they possess acceptable mechanical performance and low emittance according to this study. Furthermore, non-3D printing grade polymers may be applied in a 3D printer with caution.

Exploring Methods for Surveillance of Occupational Exposure from Additive Manufacturing in Four Different Industrial Facilities

3D printing, a type of additive manufacturing (AM), is a rapidly expanding field. Some adverse health effects have been associated with exposure to printing emissions, which makes occupational exposure studies important. There is a lack of exposure studies, particularly from printing methods other than material extrusion (ME). The presented study aimed to evaluate measurement methods for exposure assessment in AM environments and to measure exposure and emissions from four different printing methods [powder bed fusion (PBF), material extrusion (ME), material jetting (MJ), and vat photopolymerization] in industry. Structured exposure diaries and volatile organic compound (VOC) sensors were used over a 5-day working week. Personal and stationary VOC samples and real-time particle measurements were taken for 1 day per facility. Personal inhalable and respirable dust samples were taken during PBF and MJ AM. The use of structured exposure diaries in combination with measurement data revealed that comparatively little time is spent on actual printing and the main exposure comes from post-processing tasks. VOC and particle instruments that log for a longer period are a useful tool as they facilitate the identification of work tasks with high emissions, highlight the importance of ventilation and give a more gathered view of variations in exposure. No alarming levels of VOCs or dust were detected during print nor post-processing in these facilities as adequate preventive measures were installed. As there are a few studies reporting negative health effects, it is still important to keep the exposure as low as reasonable.

Influence of polymer additives on gas-phase emissions from 3D printer filaments

A collection of six commercially available, 3D printer filaments were analyzed with respect to their gas-phase emissions, specifically volatile organic compounds (VOCs), during simulated fused filament fabrication (FFF). Filaments were chosen because they were advertised to contain metal particles or carbon nanotubes. During experimentation, some were found to contain other non-advertised additives that greatly influenced gas-phase emissions. Three polylactic acid (PLA) filaments containing either copper, bronze, or stainless steel particles were studied along in addition to three carbon nanotube (CNT) filaments made from PLA, acrylonitrile-butadiene-styrene (ABS), and polycarbonate (PC). The metal-additive PLA filaments were found to emit primarily lactide, acetaldehyde, and 1-chlorododecane. The presence of metal particles in the PLA is a possible cause of the increased total emissions, which were higher than any other PLA filament reported in the literature. In addition, the filament with stainless steel particles had a threefold increase in total VOCs compared to the copper and bronze particles. Two of three CNT-containing filaments emitted compounds that have not been reported before for PLA and PC. A comparison between certain emitted VOCs and their suggested maximum inhalation limits shows that printing as little as 20 g of certain filaments in a small, unventilated room can subject the user to hazardous concentrations of multiple toxic VOCs with carcinogenic properties (e.g., acetaldehyde, 1,4-dioxane, and bis(2-ethylhexyl) phthalate). The use of certain additives, whether advertised or not, should be reevaluated due to their effects on VOC emissions during 3D printing.

Toxicity risks of occupational exposure in 3D printing and bioprinting industries: A systematic review

3-Dimensional (3D) printing and bioprinting are the new technologies. In 3D printing, synthetic polymers such as acrylonitrile, butadiene, and styrene, polylactic acid, nylon, and some metals are used as feedstocks. During 3D printing, volatile organic compounds (VOCs) and nanoparticles can be released. In the bioprinting process, natural polymers are most commonly used. All of these materials have direct and indirect toxic effects in exposed people. Therefore, the aim of this study was to provide a comprehensive review of toxicity risks due to occupational exposure to pollutants in the 3D printing and bioprinting industries. The Cochrane review method was used as a guideline for systematic review. Articles were searched in the databases including PubMed, Scopus, Web of Science, and Google Scholar. This systematic review showed that VOCs and ultra-fine particles are often released in fused deposition modeling and selective laser sintering, respectively. Asthma, chronic obstructive pulmonary disease, allergic rhinitis, and DNA damage were observed in occupational exposure to synthetic polymers. Metal nanoparticles can induce adverse health effects on the respiratory and nervous systems. This study emphasized the need to further study the toxicity of 3D printing and bioprinting-induced air pollutants. Also, consideration of safety and health principles is necessary in 3D printing and bioprinting workplaces.

Fates and spatial variations of accumulation mode particles in a multi-zone indoor environment during the HOMEChem campaign

Studying the indoor dynamics that impact particles is crucial in order to understand indoor air chemistry and assess overall human exposure to particles. This work investigates spatial gradients in particle concentration, caused by indoor transport and loss mechanisms. We conducted a variety of cooking experiments during the House Observations of Microbial and Environmental Chemistry (HOMEChem) campaign in June 2018 that allowed us to probe these mechanisms. We measured size-resolved (0.06-1 μm and 0.13-3 μm) particle number concentrations from cooking experiments using optical instruments at four locations throughout the house simultaneously. The particle number concentration in the kitchen was 40 ± 10% and 70 ± 10% higher than the concentrations in the living room and the bedroom, respectively. There was a minor size dependence, with larger differences in the smaller sizes of the accumulation mode (0.1-2.5 μm) than the larger end of the range. Dilution accounts for the majority of these concentration differences. Surface deposition was the dominant fate of particles within a zone, with observed deposition velocities ranging from 0.1 to 0.6 m h-1.

Technical control of nanoparticle emissions from desktop 3D printing

Material extrusion (ME) desktop 3D printing is known to strongly emit nanoparticles (NP), and the need for risk management has been recognized widely. Four different engineering control measures were studied in real-life office conditions by means of online NP measurements and indoor aerosol modeling. The studied engineering control measures were general ventilation, local exhaust ventilation (LEV), retrofitted enclosure, and retrofitted enclosure with LEV. Efficiency between different control measures was compared based on particle number and surface area (SA) concentrations from which SA concentration was found to be more reliable. The study found out that for regular or long-time use of ME desktop 3D printers, the general ventilation is not sufficient control measure for NP emissions. Also, the LEV with canopy hood attached above the 3D printer did not control the emission remarkably and successful position of the hood in relation to the nozzle was found challenging. Retrofitted enclosure attached to the LEV reduced the NP emissions 96% based on SA concentration. Retrofitted enclosure is nearly as efficient as enclosure attached to the LEV (reduction of 89% based on SA concentration) but may be considered more practical solution than enclosure with LEV.

Optimization of Extrusion-Based 3D Printing Process Using Neural Networks for Sustainable Development

Technological and material issues in 3D printing technologies should take into account sustainable development, use of materials, energy, emitted particles, and waste. The aim of this paper is to investigate whether the sustainability of 3D printing processes can be supported by computational intelligence (CI) and artificial intelligence (AI) based solutions. We present a new AI-based software to evaluate the amount of pollution generated by 3D printing systems. We input the values: printing technology, material, print weight, etc., and the expected results (risk assessment) and determine if and what precautions should be taken. The study uses a self-learning program that will improve as more data are entered. This program does not replace but complements previously used 3D printing metrics and software.

Monitoring of Particulate Matter Emissions from 3D Printing Activity in the Home Setting

Consumer-level 3D printers are becoming increasingly prevalent in home settings. However, research shows that printing with these desktop 3D printers can impact indoor air quality (IAQ). This study examined particulate matter (PM) emissions generated by 3D printers in an indoor domestic setting. Print filament type, brand, and color were investigated and shown to all have significant impacts on the PM emission profiles over time. For example, emission rates were observed to vary by up to 150-fold, depending on the brand of a specific filament being used. Various printer settings (e.g., fan speed, infill density, extruder temperature) were also investigated. This study identifies that high levels of PM are triggered by the filament heating process and that accessible, user-controlled print settings can be used to modulate the PM emission from the 3D printing process. Considering these findings, a low-cost home IAQ sensor was evaluated as a potential means to enable a home user to monitor PM emissions from their 3D printing activities. This sensing approach was demonstrated to detect the timepoint where the onset of PM emission from a 3D print occurs. Therefore, these low-cost sensors could serve to inform the user when PM levels in the home become elevated significantly on account of this activity and furthermore, can indicate the time at which PM levels return to baseline after the printing process and/or after adding ventilation. By deploying such sensors at home, domestic users of 3D printers can assess the impact of filament type, color, and brand that they utilize on PM emissions, as well as be informed of how their selected print settings can impact their PM exposure levels.

Emission of particulate and gaseous pollutants from household laser processing machine

Indoor air quality (IAQ) directly affects the health of occupants. Household manufacturing equipment (HME) used for hobbies or educational purposes is a new and unexplored source of air pollution. In this study, we evaluated the characteristics of particulate and gaseous pollutants produced by a household laser processing equipment (HLPE). Various target materials were tested using a commercial HLPE under various operating conditions of laser power and sheath air flow rate. The mode diameters of the emitted particles gradually decreased as laser power increased, while the particle number concentration (PNC) and particle emission rate (PER) increased. In addition, as the sheath air flow rate quadrupled from 10 to 40 L/min, the mode diameter of the emitted particles decreased by nearly 25%, but the effect on the PNC was insignificant. When the laser induced the target materials at 53 mW, the mode diameters of particles were <150 nm, and PNCs were >2.0 × 10⁴ particles/cm³. Particularly, analyses of sampled aerosols indicated that harmful substances such as sulfur and barium were present in particles emitted from leather. The carcinogenic gaseous pollutants such as acrylonitrile, acetaldehyde, 1,3-butadiene, benzene, and C₈ aromatics (ethylbenzene) were emitted from all target materials. In an actual indoor environment, the PNC of inhalable ultrafine particles (UFPs) was >5 × 10⁴ particles/cm³ during 30 min of HLPE operation. Our results suggest that more meticulous control methods are needed, including the use of less harmful target materials along with filters or adsorbents that prevent emission of pollutants.

Large-Format Additive Manufacturing and Machining Using High-Melt-Temperature Polymers. Part I: Real-Time Particulate and Gas-Phase Emissions

The literature on emissions during material extrusion additive manufacturing with 3-D printers is expanding; however, there is a paucity of data for large-format additive manufacturing (LFAM) machines that can extrude high-melt-temperature polymers. Emissions from two LFAM machines were monitored during extrusion of six polymers: acrylonitrile butadiene styrene (ABS), polycarbonate (PC), high-melt-temperature polysulfone (PSU), poly(ether sulfone) (PESU), polyphenylene sulfide (PPS), and Ultem (poly(ether imide)). Particle number, total volatile organic compound (TVOC), carbon monoxide (CO), and carbon dioxide (CO2) concentrations were monitored in real-time. Particle emission rate values (no./min) were as follows: ABS (1.7 × 1011 to 7.7 × 1013), PC (5.2 × 1011 to 3.6 × 1013), Ultem (5.7 × 1012 to 3.1 × 1013), PPS (4.6 × 1011 to 6.2 × 1012), PSU (1.5 × 1012 to 3.4 × 1013), and PESU (2.0 to 5.0 × 1013). For print jobs where the mass of extruded polymer was known, particle yield values (g-1 extruded) were as follows: ABS (4.5 × 108 to 2.9 × 1011), PC (1.0 × 109 to 1.7 × 1011), PSU (5.1 × 109 to 1.2 × 1011), and PESU (0.8 × 1011 to 1.7 × 1011). TVOC emission yields ranged from 0.005 mg/g extruded (PESU) to 0.7 mg/g extruded (ABS). The use of wall-mounted exhaust ventilation fans was insufficient to completely remove airborne particulate and TVOC from the print room. Real-time CO monitoring was not a useful marker of particulate and TVOC emission profiles for Ultem, PPS, or PSU. Average CO2 and particle concentrations were moderately correlated (r s = 0.76) for PC polymer. Extrusion of ABS, PC, and four high-melt-temperature polymers by LFAM machines released particulate and TVOC at levels that could warrant consideration of engineering controls. LFAM particle emission yields for some polymers were similar to those of common desktop-scale 3-D printers.

Estimates of particulate matter inhalation doses during three-dimensional printing: How many particles can penetrate into our body?

Harmful emissions including particulates, volatile organic compounds, and aldehydes are generated during three-dimensional (3D) printing. Ultrafine particles are particularly important due to their ability to penetrate deep into the lung. We modeled inhalation exposure by particle size during 3D printing. A total of six thermoplastic filaments were used for printing under manufacturer's recommended conditions, and particle emissions in the size range between 10 nm and 10 μm were measured. The inhalation exposure dose including inhaled and deposited doses was estimated using a mathematical model. For all materials, the number of particles between 10 nm and 1 μm accounted for a large proportion among the released particles, with nano-sized particles being the dominant size. More than 1.3 × 10⁹ nano-sized particles/kgbw/g (95.3 ± 104.0 ng/kgbw/g) could be inhaled, and a considerable amount was deposited in respiratory regions. The total deposited dose in terms of particle number was 3.1 × 10⁸ particles/kgbw/g (63.6% of the total inhaled dose), and most (41.3%) were deposited in the alveolar region. The total mass of particles deposited was 19.8 ± 16.6 ng/kgbw/g, with 10.1% of the total mass deposited in the alveolar region. Given our findings, the inhalation exposure level is mainly determined by printing conditions, particularly the filament type and manufacturer-recommended extruder temperature.

3D Printed Masks for Powders and Viruses Safety Protection Using Food Grade Polymers: Empirical Tests

The production of 3D printed safety protection devices (SPD) requires particular attention to the material selection and to the evaluation of mechanical resistance, biological safety and surface roughness related to the accumulation of bacteria and viruses. We explored the possibility to adopt additive manufacturing technologies for the production of respirator masks, responding to the sudden demand of SPDs caused by the emergency scenario of the pandemic spread of SARS-COV-2. In this study, we developed different prototypes of masks, exclusively applying basic additive manufacturing technologies like fused deposition modeling (FDM) and droplet-based precision extrusion deposition (db-PED) to common food packaging materials. We analyzed the resulting mechanical characteristics, biological safety (cell adhesion and viability), surface roughness and resistance to dissolution, before and after the cleaning and disinfection phases. We showed that masks 3D printed with home-grade printing equipment have similar performances compared to the industrial-grade ones, and furthermore we obtained a perfect face fit by customizing their shape. Finally, we developed novel approaches to the additive manufacturing post-processing phases essential to assure human safety in the production of 3D printed custom medical devices.

Energy and Eco-Impact Evaluation of Fused Deposition Modeling and Injection Molding of Polylactic Acid

There is limited knowledge about energy and carbon emission performance comparison between additive fused deposition modeling (FDM) and consolidation plastic injection molding (PIM) forming techniques, despite their recent high industrial applications such as tools and fixtures. In this study, developed empirical models focus on the production phase of the polylactic acid (PLA) thermoplastic polyester life cycle while using FDM and PIM processes to produce American Society for Testing and Materials (ASTM) D638 Type IV dog bone samples to compare their energy consumption and eco-impact. It was established that energy consumption by the FDM layer creation phase dominated the filament extrusion and PLA pellet production phases, with, overwhelmingly, 99% of the total energy consumption in the three production phases combined. During FDM PLA production, about 95.5% of energy consumption was seen during actual FDM part building. This means that the FDM process parameters such as infill percentage, layer thickness, and printing speed can be optimized to significantly improve the energy consumption of the FDM process. Furthermore, plastic injection molding consumed about 38.2% less energy and produced less carbon emissions per one kilogram of PLA formed parts compared to the FDM process. The developed functional unit measurement models can be employed in setting sustainable manufacturing goals for PLA production.

The Effect of a Phase Change on the Temperature Evolution during the Deposition Stage in Fused Filament Fabrication

Additive Manufacturing Techniques such as Fused Filament Fabrication (FFF) produce 3D parts with complex geometries directly from a computer model without the need of using molds and tools, by gradually depositing material(s), usually in layers. Due to the rapid growth of these techniques, researchers have been increasingly interested in the availability of strategies, models or data that may assist process optimization. In fact, 3D printed parts often exhibit limited mechanical performance, which is usually the result of poor bonding between adjacent filaments. In turn, the latter is influenced by the temperature field history during deposition. This study aims at evaluating the influence of the phase change from the melt to the solid state undergone by semi-crystalline polymers such as Polylactic Acid (PLA), on the heat transfer during the deposition stage. The energy equation considering solidification is solved analytically and then inserted into a MatLab® code to model cooling in FFF. The deposition and cooling of simple geometries is studied first, in order to assess the differences in cooling of amorphous and semi-crystalline polymers. Acrylonitrile Butadiene Styrene (ABS) was taken as representing an amorphous material. Then, the deposition and cooling of a realistic 3D part is investigated, and the influence of the build orientation is discussed.

Characterization of Ultrafine Particles and VOCs Emitted from a 3D Printer

Currently, widely available three-dimensional (3D) printers are very popular with the public. Previous research has shown that these printers can emit ultrafine particles (UFPs) and volatile organic compounds (VOCs). Several studies have examined the emissivity of filaments from 3D printing, except glycol modified polyethylene terephthalate (PETG) and styrene free co-polyester (NGEN) filaments. The aim of this study was to evaluate UFP and VOC emissions when printing using a commonly available 3D printer (ORIGINAL PRUSA i3 MK2 printer) using PETG and NGEN. The concentrations of UFPs were determined via measurements of particle number concentration and size distribution. A thermal analysis was carried out to ascertain whether signs of fiber decomposition would occur at printing temperatures. The total amount of VOCs was determined using a photoionization detector, and qualitatively analyzed via gas chromatography-mass spectrometry. The total particle concentrations were 3.88 × 10¹⁰ particles for PETG and 6.01 × 10⁹ particles for NGEN. VOCs at very low concentrations were detected in both filaments, namely ethylbenzene, toluene, and xylene. In addition, styrene was identified in PETG. On the basis of our results, we recommend conducting additional measurements, to more accurately quantify personal exposure to both UFPs and VOCs, focusing on longer exposure as it can be a source of potential cancer risk.

Regulatory developments and their impacts to the nano-industry: A case study for nano-additives in 3D printing

Nanotechnology has increasing applications in numerous markets, particularly in additive processing (3D printing) and manufacturing, which is important for consumer products, medical devices, construction, and general research and development across many other industries. Nanomaterials are desirable in many products due to their unique properties, but those same properties have made evaluating the risk and regulation of these materials challenging. For risk-based regulations, new applications and nanomaterials should be assessed for both human and environmental hazards and exposure to ensure protection. In general, many risk assessments to date have focused on the non-nano versions of chemicals. The lack of guidance on assessing the hazard and exposure of nanomaterials in 3D printing is apparent, and these areas of assessment are actively being evaluated. Industry in most cases will now need to provide specific additional information for assessing the risk of nanomaterials in 3D printing. This review paper focuses on the use of nanomaterials in 3D printing for industrial and manufacturing applications, summarizes the current literature on human health and safety related to 3D printing and inhalation exposure, and the regulations relating to 3D printing in the U.S., Canada, and Europe for this industry.

Characterization of ultrafine particles emitted during laser-based additive manufacturing of metal parts

Particulate matter (PM) emitted during laser additive manufacturing with stainless steel powder materials has been studied in detail. Three different additive manufacturing techniques were studied: selective laser melting, direct metal deposition and laser cladding. Gas flow and temperature fields accompanying the processes were numerically modeled for understanding particle growth and oxidation. Transmission and scanning electron microscopy were used for primary particle and PM characterization. The PM collected in the atmosphere during manufacturing consisted of complex aggregates/agglomerates with fractal-like geometries. The overwhelming number of particles formed in the three processes had equivalent projected area diameters within the 4-16 nm size range, with median sizes of 8.0, 9.4 and 11.2 nm. The primary particles were spherical in shape and consisted of oxides of the main steel alloying elements. Larger primary particles (> 30 nm) were not fully oxidized, but where characterized by a metallic core and an oxidic surface shell.

Dynamic Analysis of Particle Emissions from FDM 3D Printers through a Comparative Study of Chamber and Flow Tunnel Measurements

Ultrafine particle emissions originating from fused deposition modeling (FDM) three-dimensional (3D) printers have received widespread attention recently. However, the obvious inconsistency and uncertainty in particle emission rates (PERs, #/min) measured by chamber systems still remain, owing to different measurement conditions and calculation models used. Here, a dynamic analysis of the size-resolved PER is conducted through a comparative study of chamber and flow tunnel measurements. Two models to resolve PER from the chamber and a model for flow tunnel measurements were examined. It was found that chamber measurements for different materials underestimated PER by up to an order of magnitude and overestimated particle diameters by up to 2.3 times, while the flow tunnel measurements provided more accurate results. Field measurements of the time-resolved particle size distribution (PSD) in a typical room environment could be predicted well by the flow tunnel measurements, while the chamber measurements could not represent the main PSD characteristics (e.g., particle diameter mode). Secondary aerosols (>30 nm) formed in chambers were not observed in field measurements. Flow tunnel measurements were adopted for the first time as a possible alternative for the study of 3D printer emissions to overcome the disadvantages in chamber methods and as a means to predict exposure levels.

Exposure, assessment and health hazards of particulate matter in metal additive manufacturing: A review

Metal additive manufacturing (AM), also known as metal three-dimensional (3D) printing, is a new technology offering design freedom to create complex structures that has found increasing applications in industrial processes. However, due to the fine metal powders and high temperatures involved, the printing process is likely to generate particulate matter (PM) that has a detrimental impact on the environment and human health. Therefore, comprehensive assessement of the exposure and health hazards of PM pollution related to this technique is urgently required. This review provides general knowledge of metal AM and its possible particle release. The health issues of metal PM are described considering the exposure routes, adverse human health outcomes and influencing factors. Methods of evaluating PM exposure and risk assessment techniques are also summarized. Lastly, future research needs are suggested. The information and knowledge presented in this review will contribute to the understanding, assessment, and control of possible risks in metal AM and benefit the wider metal 3D printing community, which includes machine operators, consumers, R&D scientists, and policymakers.