Background

3D printing refers to processes that additively manufacture a product layer by layer. The layers may be fused by physical means or by chemical reactions. Hazards associated with 3D printers include not only those related to the material being printed, but also with post-processing of printed objects and with printer cleaning and maintenance.

Top-down view of a 3D printer in operation at the Jackson Innovation Studio on campus

Common Hazards Associated with 3D Printing

• Mechanical: Moving parts may cause injury. Machine guards and enclosures must not be bypassed while the printer is in operation. Use all guards and enclosures provided with the 3D printer.
• Electrical: As with all devices powered by electricity, there is a risk of electrical shock with 3D printers. Follow general electrical safety practices while using 3D printers, including plugging the printer directly into an outlet without the use of an extension cord.
• Hot surfaces: 3D printer components such as print heads, build surfaces, and UV lamps can become hot during printer operation and may cause burns.
• Chemical:
  • Common 3D printer feedstocks such as polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) produce ultrafine particle and VOC emissions, which are associated with adverse health effects. 3D printers should only be used in spaces with adequate ventilation, and models with enclosures and/or exhaust filtration are preferred.
  • Flammable and/or toxic solvents are required for some 3D printing processes. They may be used as components of 3D printing material (such as resins), to finish structures after printing, or to clean and maintain 3D printer parts. These chemicals should only be used in a well-ventilated area such as a fume hood. Users should wear appropriate PPE, as listed on the chemical Safety Data Sheets. More information about safely handling flammable liquids may be found here.
  • Some 3D printing procedures use corrosive chemicals such as a base bath to remove support structures after printing. Users should work in a well-ventilated area and wear PPE appropriate for the chemical hazards present, as listed on the Safety Data Sheets. Corrosives should only be used in a space with access to emergency flushing equipment.
• UV: Some 3D printing processes use UV lamps to cure material into a solid state. Use safety glasses with UV protection features and do not look directly into the UV lamp.
• Compressed gases: 3D printers operating under an inert atmosphere may require the use of compressed gas cylinders. More information about compressed gas safety may be found here.

Material Extrusion 3D Printing

Material extrusion is the most commonly used 3D printing process found on campus and includes Fused Deposition Modeling (FDM) printers. In this process, a heated filament of material is selectively dispensed through an orifice to build an object layer by layer. The printed object may then be modified to remove support structures or treated with solvents to produce the desired surface finish.

Polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and nylon are commonly used feedstock materials for FDM printers. When heated during the printing process, these filaments produce ultrafine particles (UFPs) and volatile organic compounds (VOCs) that are associated with adverse health effects. Additional hazards associated with material extrusion printers include the risk of burns from heated components and exposure to chemical solvents used in bed preparation or post-processing work.

Material extrusion 3D printers at the Jackson Innovation Studio on campus

Safety Provisions for Material Extrusion 3D Printing:

• If possible, purchase a printer that meets the ANSI/CAN/UL 2904 standard, which sets guidelines for chemical and particle emissions by 3D printers.
• Select a printer equipped with an enclosure, exhaust line, and/or HEPA filtration system.
• Install the printer in a space with adequate ventilation. Avoid operating 3D printers in small rooms such as offices and closets. Laboratory spaces are generally designed to have more air changes per hour (ACH) and are a better option for 3D printer installation than office spaces.
• Follow the manufacturer’s instructions for installation and use.
• Use engineering controls to improve ventilation, such as a fume hood, fume extractor, or room air HEPA filter.
• Keep accessible copies of Safety Data Sheets (SDS) for all chemicals involved in the printing process (including feedstocks, post-processing reagents, and cleaning solvents) and use PPE prescribed therein.
• Develop a Standard Operating Procedure for using the 3D printer and ensure all personnel are trained before allowing access to the printer.
• Select the lowest hazard printing material for your needs. For example, PLA requires a lower printing temperature and releases fewer particles and VOCs than ABS and nylon.
• Purchase feed stocks recommended by the manufacturer for use with your printer.
• Reduce your exposure to 3D printer emissions by minimizing the time you spend around the printer while it is in operation. If possible, leave the room and monitor the print job remotely.
• Clean the extrusion nozzle and build plate after the 3D printer has finished operating and has completely cooled down. Filament buildup can contribute to airborne emissions during printer operation.
• Wipe down the 3D printer and surrounding surfaces with a wet cloth or paper towel after use.
• Wash your hands after working with the 3D printer or any of its associated supplies.
• Do not eat, drink, or apply cosmetics in the room where the 3D printer is located.
• If you have questions about best practices for choosing, installing, and/or operating your 3D printer, contact your college or department’s safety professionals or email DRS at DRS@illinois.edu.

Hazards Posed by Other Types of 3D Printers

If you are considering using a 3D printer with hazards outside those described above, please contact the safety office in your college or department, or reach out to the Division of Research Safety. The following are just a few examples of other 3D printer hazards which could require a hazard assessment before installation.

Resins: Some 3D printers produce solid objects by selectively curing liquid resin. Resins may be associated with a range of hazards, including skin and respiratory irritation if exposed. Users should not handle printer resin without appropriate PPE as described in the Safety Data Sheet (SDS). Resin 3D printers should only be installed in spaces with adequate ventilation. Spilled resin is difficult to completely remove from carpeting, so these printers should be used only in spaces with hard flooring.

Metal powders: Some 3D printers use powdered feedstocks such as glass, ceramic, or metal. The powdered material may pose a risk of adverse health effects through inhalation or dermal exposure. Metal powders may create a hazard of ignition or explosion when dispersed in the air.

Lasers: Some 3D printers use a focused energy source, such as a laser, to fuse material into a solid object. More information about lasers and their associated hazards can be found here.