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Additive Manufacturing for Occupational Hygiene: A Comprehensive Review of Processes, Emissions, & Exposures.
A B Stefaniak1, S Du Preez2, J L Du Plessis2
1Respiratory Health Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA.
Summary
Occupational hygienists and toxicologists can now identify airborne particles and organic gases emitted from various additive manufacturing (AM) processes. This review details emissions from powder bed fusion, material extrusion, and other AM methods, aiding worker safety assessments.
Area of Science:
- Occupational Health and Safety
- Industrial Hygiene
- Toxicology
- Additive Manufacturing (AM) Emissions
Background:
- Additive manufacturing (AM) encompasses diverse processes with varying emission profiles.
- Understanding airborne contaminants is crucial for protecting worker health in AM environments.
- Existing research often lacks comprehensive real-world emission data across all AM categories.
Purpose of the Study:
- To provide a comprehensive review of airborne emissions from seven basic AM process categories.
- To inform occupational hygienists and toxicologists about particle and gas releases.
- To identify knowledge gaps and recommend future research directions for AM exposure assessment.
Main Methods:
- Systematic literature review of 46 articles reporting real-world measurements for AM processes.
- Categorization of AM processes including Powder Bed Fusion (PBF), Material Jetting (MJ), Material Extrusion (ME), Directed Energy Deposition (DED), and Binder Jetting (BJ).
- Analysis of particle size distribution, chemical composition, and volatile organic compound (VOC) releases.
Main Results:
- PBF, MJ, ME, and DED processes release nanoscale to submicron particles; BJ releases larger particles up to 8.5 µm.
- Metallic feedstock AM (PBF, DED) releases hazardous metals (Cr, Mn, Ni); polymer feedstock AM releases organic gases (e.g., benzene, formaldehyde).
- Real-time monitoring tools like mobility sizers and photoionization detectors are effective for specific emission types.
Conclusions:
- Significant differences exist in particle and gas emissions across AM processes, necessitating tailored exposure assessments.
- Further research is required on facility, machine, and feedstock factors, dermal exposure, and task-based exposures.
- Harmonized monitoring approaches are essential for comparing AM emission and exposure data to ensure worker safety.
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