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

Area of Science:

• Additive Manufacturing
• Occupational Health
• Nanoparticle Science

Background:

• Laser Powder Bed Fusion (L-PBF) is a key Additive Manufacturing (AM) technology with broad industrial use.
• Occupational exposure limits for nanoparticles (NP) from L-PBF processes are not well-established.
• Understanding NP release patterns is crucial for worker safety in AM facilities.

Purpose of the Study:

• To assess nanoparticle release patterns during L-PBF operations in research settings.
• To identify factors influencing NP concentration and size during L-PBF.
• To provide data for establishing occupational exposure benchmarks and improving safety guidelines.

Main Methods:

• Conducted environmental and personal real-time monitoring of NP concentration and size in two L-PBF facilities.
• Monitored processes using stainless steel, aluminum-silicon alloy, and pure copper feedstock.
• Measured temperature and relative humidity during environmental monitoring.

Main Results:

• Monitored L-PBF processes showed controlled NP release, with average operator exposure below proposed limits.
• Specific tasks, particularly warm-up and cleaning, led to significant NP release events, especially with pure copper.
• Operator actions, relative humidity, and device setup impacted NP release amount and size.

Conclusions:

• L-PBF operations can result in controlled NP exposure, but specific tasks pose risks.
• Identifying and mitigating NP release events during warm-up, cleaning, and specific material processing is essential.
• Findings inform improved operational conditions and safety protocols for L-PBF additive manufacturing.