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

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