Reducing particulate emissions from 3D printers using low-cost enclosures and engineering controls

Previous studies have shown that emissions from 3D printing can impact worker health. To address this concern, this study aims to evaluate the efficacy of low-cost engineering controls in reducing particle emissions from two fused filament fabrication (FFF) 3D printers. Controls included four custom designs using 3D printed parts, a blower fan, and HEPA filters (Controls A-D); two low-cost fume extractors (Controls E and F); exhaust ventilation to outdoor air (Control G); along with two enclosures, one flexible (Enclosure 1) and one rigid (Enclosure 2).

Each control and enclosure was evaluated with two different FFF 3D printers in an emissions test chamber. Control efficiency was quantified by comparing average particle emissions at the chamber outlet with and without the controls and enclosures in place, while printing the National Institute of Standards and Technology test artifact with acrylonitrile butadiene styrene filament.

The minimum control efficiencies (MCE), the lowest efficiency measured for each control at the lower limit of the 95% confidence interval, of Controls A-G ranged from 84.36 to 99.95% for both printers. Control G was the most effective with an MCE ≥ 98.35% for both printers, while Control F was the least effective with an MCE ≥ 84.36% for both. The MCEs of Enclosures 1 and 2 were 91.2% and 80.2% for Printer A and 94.97% and 67.3% for Printer B.

This study demonstrated that low-cost engineering controls and enclosures that are not printer or material specific can be integrated with FFF 3D printing technologies to reduce particle emissions during 3D printing processes to protect worker health.