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Updated: Sep 1, 2025

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

Aleksandr B Stefaniak1, Lauren N Bowers1, Stephen B Martin1

  • 1National Institute for Occupational Safety and Health, Morgantown, West Virginia 26505, United States.

Journal of Chemical Health & Safety
|August 18, 2022
PubMed
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This summary is machine-generated.

Large-format additive manufacturing (LFAM) of high-melt-temperature polymers releases significant particulate and total volatile organic compounds (TVOC). Engineering controls may be necessary to mitigate airborne emissions from these 3-D printing processes.

Area of Science:

  • Additive Manufacturing
  • Polymer Science
  • Environmental Health

Background:

  • Literature on 3-D printer emissions is growing, but data for large-format additive manufacturing (LFAM) using high-melt-temperature polymers is scarce.
  • LFAM machines are increasingly used for industrial applications, necessitating an understanding of their environmental impact.

Purpose of the Study:

  • To quantify and characterize airborne emissions, including particles and total volatile organic compounds (TVOC), from two LFAM machines during the extrusion of various polymers.
  • To assess the effectiveness of standard ventilation systems in controlling these emissions.
  • To compare emission profiles of LFAM with desktop-scale 3-D printers.

Main Methods:

  • Real-time monitoring of particle number, TVOC, carbon monoxide (CO), and carbon dioxide (CO2) concentrations during polymer extrusion.
Keywords:
3-D printingadditive manufacturingultrafine particlesvolatile organic compounds

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  • Measurement of particle emission rates (no./min) and particle yields (g-1 extruded).
  • Calculation of TVOC emission yields (mg/g extruded).

    • Main Results:

    • Significant particle emissions were observed for all tested polymers, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polysulfone (PSU), poly(ether sulfone) (PESU), polyphenylene sulfide (PPS), and Ultem.
    • TVOC emission yields varied by polymer, with ABS showing the highest yield (0.7 mg/g).
    • Standard exhaust ventilation was insufficient to remove all airborne contaminants. CO monitoring was not a reliable indicator for all polymers, though CO2 showed moderate correlation with particle concentration for PC.

    Conclusions:

    • Extrusion of ABS, PC, and four high-melt-temperature polymers via LFAM generates particulate and TVOC at levels suggesting the need for engineering controls.
    • LFAM particle emission yields can be comparable to those of smaller-scale 3-D printers.
    • Further research into emission control strategies for LFAM is warranted.