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Related Experiment Video

Updated: Jul 23, 2025

3D Printing - Evaluating Particle Emissions of a 3D Printing Pen
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Integrating Exposure Assessment and Process Hazard Analysis: The Nano-Enabled 3D Printing Filament Extrusion Case.

Stratos Saliakas1, Spyridon Damilos1, Melpo Karamitrou2

  • 1Innovation in Research & Engineering Solutions (IRES), 1780 Wemmel, Belgium.

Polymers
|July 14, 2023
PubMed
Summary

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Polymers·2026

This study assesses nanoparticle exposure during 3D printing filament production from recycled plastics. Findings inform safety protocols for novel nanocomposite materials in manufacturing.

Area of Science:

  • Materials Science and Engineering
  • Occupational Health and Safety
  • Additive Manufacturing

Background:

  • Nanoparticles enhance thermoplastic properties for applications in automotive, sports, and consumer goods via additive manufacturing.
  • Limited data exists on health and safety during the production of nanocomposites, especially from recycled materials.

Purpose of the Study:

  • To assess nano- and micro-particle exposure during 3D printing filament production using recycled thermoplastics (TPU, PA12) reinforced with iron oxide nanoparticles (Fe3O4 NPs).
  • To identify potential failure modes and implement corrective actions for safe production processes.

Main Methods:

  • Exposure assessment via near- and far-field measurements during compounding and extrusion of recycled TPU and PA12 nanocomposites.
  • Utilized portable devices to measure particulate emissions in the workers' inhalable zone.
Keywords:
exposure assessmentnanocompositesoccupational safetypolymer extrusion

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Last Updated: Jul 23, 2025

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  • Conducted Failure Modes and Effects Analysis (FMEA) and Failure Tree Analysis (FTA) to document process deviations and identify critical failure events.

    • Main Results:

    • Characterized particle emissions from recycled thermoplastic nanocomposites during filament extrusion.
    • Identified critical process deviations and failure modes through FMEA and FTA.
    • Proposed corrective actions to mitigate risks associated with nanoparticle exposure.

    Conclusions:

    • The study provides crucial health and safety insights for producing 3D printing filaments from recycled nanocomposites.
    • Risk assessment methodologies (FMEA, FTA) are vital for ensuring worker safety in advanced material manufacturing.
    • Reinforcement with Fe3O4 NPs offers matrix healing properties, necessitating careful exposure control during production.