Occupational Exposure to Ultrafine Particles in Metal Additive Manufacturing: A Qualitative and Quantitative Risk Assessment

An analysis on control banding-based methods used for occupational risk assessment of nanomaterials

Despite all benefits of nanomaterials, their unique characteristics made them an emerging hazard in workplaces, which need to be assessed for their potential risks. So, the aim of this study was to review all the studies conducted on the risk assessment of activities involving nanomaterials with CB-based methods.This study is based on a literature review on databases including Web of science, Scopus, PubMed, and SID. After reviewing and screening studies according to PRISMA, the collected data were meta-analyzed by Comprehensive Meta-Analysis Software. Also, Newcastle-Ottawa checklist was used for quality assessment of the studies. To determine similarity of methods, Cohen's Kappa was used. Sensitivity analysis was used to determine the role of each factor in the risk assessment by using the Crystal Ball tool.There are eight validated methods for risk assessment. Also, some authors used a self-deigned tool based on CB approach. The results of meta-analysis showed that the odds ratio for the risk of activities involved with nanomaterials was 0.654 (high risk). Results of simulation for Nanotool showed that the mean risk level of activities involved with nanomaterials, with a certainty of 95.07%, is moderate (RL3). Moreover, sensitivity analysis showed that the risk was depended on "Hazard band" in all methods except ISO method.The obtained results can be useful in improving existing methods and suggesting new methods. Also, there is a need to design and propose specific methods for risk assessment of incidental and natural nanomaterials.

Assessment of nanoparticle emission in additive manufacturing: Comparing wire and powder laser metal deposition processes

Additive manufacturing (AM), often referred to as 3D printing, is an emerging technology with a wide range of industrial applications and process typologies. Although the release of metal nanoparticles as by-products could occur, occupational exposure limits and cogent safety standards are not currently available due to the novelty of the technology. To support the definition of benchmarks, this study aims to provide a preliminary comparison between the nanoparticle release patterns of laser metal deposition, adopting different feedstocks, namely, metal wire and metal powder. The monitored device is a university research setup, and the work presents the results of two different processes with AISI 316 L as a feedstock in powder and wired form, respectively. The monitoring confirmed the outcomes of previous studies, with a high release of nanoparticles from the powder head on the device (average 138,713 n/cm3 during printing, with maximum values exceeding 106 n/cm3). Moreover, the results show a significant concentration of nanoparticles with a wire head during the printing phase (average release of 628,156 n/cm3 with a maximum of 1,114,987 n/cm3) and pauses (average of 32,633 n/cm3 and a maximum of 733,779 n/cm3). The monitored values during pauses are particularly relevant since no personal protection equipment was used in the wire processes and the operators could access the printing room during pauses for device interventions, thus being exposed to significant nanoparticle concentrations. This study presents a preliminary evaluation of the potential exposure during laser metal deposition while implementing different technologies and provides evidence for defining effective operational safety procedures for the operators.

Implications of ferroptosis in silver nanoparticle-induced cytotoxicity of macrophages

Metal nanoparticles (NPs) are widely used in daily life and commercial activities owing to their unique physicochemical properties. Consequently, there is an increasing risk of daily and occupational exposure to metal NPs, which raises concerns regarding their health hazards. Programmed cell deaths (PCDs) have been clarified to be involved in metal NP-induced cytotoxicity, including apoptosis, autophagy, and pyroptosis. However, whether and how ferroptosis, a newly recognized PCD, contributes to metal NP-induced cell death remain unclear. In this study, we investigated the ferroptotic effects of two representative metal NPs, silver nanoparticles (AgNPs) and gold nanoparticles (AuNPs), on macrophages in vitro. Our results revealed that AgNPs, rather than AuNPs, induced non-apoptotic PCD, accompanied by lipid peroxidation and iron homeostasis disorders, which are two hallmarks of ferroptosis, in macrophages. Treatment with a ferroptosis inhibitor (ferrostatin-1) and iron chelator (deferoxamine) reversed AgNP-induced PCD, corroborating the induction of ferroptosis upon exposure to AgNPs. Moreover, our results revealed that smaller AgNPs elicited greater ferroptotic effects on macrophages than larger ones. Importantly, ferroptosis in AgNP-treated macrophages was mainly triggered by AgNPs per se rather than by Ag ions. Overall, our study highlights the ferroptotic effects elicited by AgNPs in macrophages, which will promote the understanding of their cytotoxic effects and facilitate the safer design of metal nanoproducts.

Characterizing Nanoparticle Release Patterns of Laser Powder Bed Fusion in Metal Additive Manufacturing: First Step Towards Mitigation Measures

Laser Powder Bed Fusion (L-PBF) is a well-known Additive Manufacturing (AM) technology with a wide range of industrial applications. Potential occupational exposures to metal nanoparticles (NP) as by-products could occur in these processes, and no cogent occupational exposure limits are available. To contribute to this assessment, a monitoring campaign to measure the NP release pattern in two metal L-PBF facilities was carried out in two academic laboratories adopting L-PBF technology for research purposes. The monitored processes deal with two devices and three feedstock types, namely stainless steel (AISI 316L), aluminium-silicon alloy (A357) and pure copper, which are associated with different levels of industrial maturity. Prolonged environmental and personal real-time monitoring of NP concentration and size were performed, temperature and relative humidity were also measured during environmental monitoring. The measurements reveal a controlled NP release of the monitored processes, resulting in an average reduced exposure of the operators during the whole working shift, in compliance with proposed limit values (20 000 n cm-3 for density >6000 kg m-3 or 40 000 n cm-3 for density <6000 kg m-3). Nonetheless, the monitoring results show release events with an increase in NP concentration and a decrease in NP size corresponding with several actions usually performed during warm-up and cleaning, leading to exposures over 40-50 000 n cm-3 during a considerable time interval, especially during the manufacturing of pure copper powder. The results show that the actions of the operators, boundary conditions (relative humidity) and set-up of the L-PBF device have an impact on the amount of NP released and their size. Several release events (significant increase in NP concentration and decrease in NP size) are identified and associated with specific job tasks of the workers as well as building conditions. These results contribute to the definition of NP release benchmarks in AM processes and provide information to improve the operational conditions of L-PBF processes as well as safety guidelines for operators.

Laboratory activities involving nanomaterials: risk assessment and investigating researchers symptoms

The increasing use of nanomaterials is a threat to human health and environment that has led to the expansion of risk assessment methods. Thus, the aim of this study was to assess the occupational risks of activities involving nanomaterials in nanomedicine research laboratories by Control Banding (CB) NanoTool and Guidance methods. Further, the symptoms of researchers working in these laboratories were investigated. This cross-sectional study was managed in nanomedicine research laboratories. Risk assessment was performed by the CB NanoTool and Guidance methods. Moreover, a questionnaire was used to assess the prevalence of non-specific symptoms. Finally, data were analyzed using the IBM SPSS software. Descriptive statistics were used for data analysis. Many activities are located on the risk level RL2 and category A based on the CB NanoTool and Guidance methods, respectively. Further, the highest severity of exposure to nanomaterials belonged to the preparation of suspension and emulsion and manufacture of metal nanopolymers, but the highest probability of exposure was in the manufacturing of carbon nanocomposites. In addition, there was a significant relationship between the level of risk in the two methods (P = 0.003). Although, cutaneous symptoms were the most common symptoms among laboratory researchers, chi-square test did not confirm any significant relationship between symptoms and risk levels (p-value >0.05) in these two methods. Since the NanoTool method uses more diverse parameters for risk assessment and is more acceptable, choosing control measures based on its results seems more reasonable. Moreover, Guidance can be used as a method for initial assessments and determine the need for further assessments.

Occupational Exposure to Incidental Nanomaterials in Metal Additive Manufacturing: An Innovative Approach for Risk Management

The benefits of metal 3D printing seem unquestionable. However, this additive manufacturing technology brings concerns to occupational safety and health professionals, since recent studies show the existence of airborne nanomaterials in these workplaces. This article explores different approaches to manage the risk of exposure to these incidental nanomaterials, on a case study conducted in a Portuguese organization using Selective Laser Melting (SLM) technology. A monitoring campaign was performed using a condensation particle counter, a canning mobility particle sizer and air sampling for later scanning electron microscopy and energy dispersive X-ray analysis, proving the emission of nano-scale particles and providing insights on number particle concentration, size, shape and chemical composition of airborne matter. Additionally, Control Banding Nanotool v2.0 and Stoffenmanager Nano v1.0 were applied in this case study as qualitative tools, although designed for engineered nanomaterials. This article highlights the limitations of using these quantitative and qualitative approaches when studying metal 3D Printing workstations. As a result, this article proposes the IN Nanotool, a risk management method for incidental nanomaterials designed to overcome the limitations of other existing approaches and to allow non-experts to manage this risk and act preventively to guarantee the safety and health conditions of exposed workers.

Comprehensive Analysis of Two H13-Type Starting Materials Used for Laser Cladding and Aerosol Particles Formed in This Process

Laser cladding with H13 steel powders was performed and the related material transformations were studied for the particles emitted during this process. Fractions of various sizes of the aerosol particles formed during the laser cladding were collected on a cascade impactor, while the electromobility and the aerodynamic size of the particles were measured using a scanning mobility particle spectrometer and an aerodynamic particle sizer, respectively. The aerosol particles deposited onto the impactor plates were analyzed using scanning electron microscopy−energy-dispersive X-ray spectroscopy, as well as total-reflection X-ray fluorescence and X-ray absorption near-edge structure spectroscopy. Both the concentration and mean oxidation state of the major components were correlated with the aerosol particle size. The ultrafine aerosol particles (with a diameter less than about 100 nm) were predominantly oxidized and formed as the result of an evaporation−oxidation−condensation process sequence. The larger particles (>200 nm in geometric diameter) were primarily the residues of the original metal powder and exhibited a composition change as compared to the as-received metal powder. Correlations between the changes in the concentration ratio of the components were detected and explained.

A Qualitative and Quantitative Occupational Exposure Risk Assessment to Hazardous Substances during Powder-Bed Fusion Processes in Metal-Additive Manufacturing

Metal-additive manufacturing (AM), particularly the powder-bed fusion (PBF) technique, is undergoing a transition from the short-run production of components to higher-volume manufacturing. The industry’s increased production efficiency is paired with a growing awareness of the risks related to the inhalation of very fine metal powders during PBF and AM processes, and there is a pressing need for a ready-to-use approach to assess the risks and the occupational exposure to these very final metal powders. This article presents a study conducted in an AM facility, which was conducted with the aim to propose a solution to monitor incidental airborne particle emissions during metal AM by setting up an analytical network for a tailored approach to risk assessment. Quantitative data about the respirable and inhalable particle and metal content were obtained by gravimetric and ICP-MS analyses. In addition, the concentrations of airborne particles (10–300 nm) were investigated using a direct reading instrument. A qualitative approach for risk assessment was fulfilled using control banding Nanotool v2.0. The results show that the operations in the AM facility are in line with exposure limit levels for both micron-sized and nano-sized particles. The particulate observed in the working area contains metals, such as chromium, cobalt, and nickel; thus, biological monitoring is recommended. To manage the risk level observed for all of the tasks during the AM process, containment and the supervision of an occupational safety expert are recommended to manage the risk. This study represents a useful tool that can be used to carry out a static evaluation of the risk and exposure to potentially harmful very fine metal powders in AM; however, due to the continuous innovations in this field, a dynamic approach could represent an interesting future perspective for occupational safety.