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Large-Format Additive Manufacturing and Machining Using High-Melt-Temperature Polymers. Part II: Characterization of

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
|September 23, 2022
PubMed
Summary
This summary is machine-generated.

Large-format additive manufacturing releases particles and gases, including endocrine disruptors like BPA and BPS, from high-melt-temperature polymers. Polymer-specific risk assessments are crucial for worker safety in 3D printing environments.

Keywords:
3-D printingadditive manufacturingasthmagensbisphenolscarcinogensirritants

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Area of Science:

  • Additive Manufacturing
  • Polymer Science
  • Occupational Health

Background:

  • Large-format additive manufacturing (LFAM) utilizes high-melt-temperature polymers, but emissions are poorly characterized.
  • Potential release of hazardous particles and gases during LFAM processes poses risks to worker health.
  • Existing data lacks comprehensive analysis of emissions from various high-melt-temperature polymers.

Purpose of the Study:

  • To characterize the physical and chemical properties of particles and gases emitted during LFAM of high-melt-temperature polymers.
  • To quantify the release of specific compounds, including endocrine disruptors and respiratory irritants.
  • To assess potential exposure routes and inform polymer-specific risk assessments for additive manufacturing workers.

Main Methods:

  • Monitored emissions from two LFAM machines extruding acrylonitrile butadiene styrene (ABS), polycarbonate (PC), Ultem, polysulfone (PSU), poly(ether sulfone) (PESU), and polyphenylene sulfide (PPS).
  • Collected filter samples for elemental analysis, bisphenol A (BPA) and S (BPS) quantification, and particle morphology visualization.
  • Quantified individual gases using substance-specific media for air analysis.

Main Results:

  • Low elemental concentrations were observed, with iron peaking at 1.6 mg/m3 during Ultem extrusion.
  • BPA was released from PC (0.4–21.3 μg/m3) and PESU (2.0–8.7 μg/m3); BPS was detected from PESU (0.03–0.07 μg/m3).
  • Contamination of work surfaces and printed parts with BPA and BPS was detected, indicating dermal exposure risks. Low levels of respiratory irritants, asthmagens, and potential occupational carcinogens were also quantified.

Conclusions:

  • Emissions from high-melt-temperature polymers during LFAM vary significantly, necessitating polymer-specific exposure and risk assessments.
  • The detection of BPA and BPS on surfaces highlights an unrecognized dermal exposure pathway for additive manufacturing workers.
  • Understanding these emissions is critical for developing effective safety protocols and mitigating occupational health risks in the 3D printing industry.