Additive Manufacturing: Methods, Hazards, and 2/15/2018 Safety Culture
Additive Manufacturing: Methods, Hazards, and Safety Culture
Gary Roth, MS, PhD Health Scientist / Associate Service Fellow
2018 Indiana Safety and Health Conference & Expo Indianapolis, IN 14 March 2018
The findings and conclusions in this presentation have not been formally disseminated by the National Institute for Occupational Safety and Health and should not be construed to represent any agency determination or policy.
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Market Impact of AM/3DP
Aerospace Automotive Electronics Consumer Medical
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Comparative Advantages
Traditional
• Established •More material options • Consistent quality • Higher throughput
Additive
• Minimal waste material •Complex features • Fewer tools • Processes easily modified
Benefits of AM/3DP
•Computer‐Aided Design (CAD) Development •Rapid iteration •More innovation space
•Novel geometries •More complex parts Products •Efficiently use high‐cost materials •Customization
•Lower material use •Fewer tools Logistics •Just‐in‐Time fulfillment •Distributed manufacturing
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Safety & Health is complex for Additive Manufacturing
Additive manufacturing is a collection of technologies (not just one)
Additive manufacturing speeds innovation, requiring continuous adaptation
Additive manufacturing is being adopted by a wide variety of users
AM METHODS
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The Basics
1. CAD 2. Build material in liquid/powder/solid form 3. Stepwise vertical (z‐ axis) motion 4. Selective x‐/y‐axis binding mechanism 5. Iterative 6. Post‐Processing
Materials & Feedstocks
Liquid Resin Solid Plastic Metal Powder
… or any permutation thereof. … or something else entirely.
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Binding/Joining Mechanisms
Curing Heat/Cooling Cementing
Taxonomy
Stereolithography Vat Polymerization Liquid Feedstock Digital Light Processing Material Jetting Fused‐Filament Material Extrusion Fabrication Solid Feedstock Sheet Lamination Selective Laser Sintering / Melting Additive Powder‐Bed Fusion Electron Beam Melting
Manufacturing Powdered Feedstock Binder Jetting Selective Heat Sintering
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Material Extrusion
Build Material
• Thermoplastic
Feedstock Form
• Solid filament
Selector
• Deposition nozzle
Binding Mechanism
•Melting
Powder Bed Fusion
Build Material
• Metal/Plastic/Ceramic
Feedstock Form
•Powdered
Selector
•Laser
Binding Mechanism
• Sintering / Melting
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Vat Polymerization
Build Material
• Photopolymer resin
Feedstock Form
• Liquid
Selector
• UV Laser/Projector
Binding Mechanism
•Curing
Binder Jetting
Build Material
• Metal/Plastic/Ceramic
Feedstock Form
•Powdered
Selector
• Printer Head
Binding Mechanism
• Adhesion/cementing
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AM WORKER HAZARDS
Holistic Perspective
Materials
Process Environment
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Materials
Polymers Solvents Metals Nanomaterials
Acrylonitrile‐butadiene‐styrene Dimethyl fumarate Ti‐6Al‐4V nFe (steel sintering) Polylactic acid Isopropanol Propylene fumarate IN 625 & IN 718 (Ni, Cr) nAg (sintering, conductivity)
Poly(vinyl alcohol) Acetone nCB, CNT (conductivity, 17‐4 PH stainless steel Polycarbonate stiffness, tensile strength) Methyl Ethyl Ketone Polyethylene
Cobalt chromium nSiOx (polymer strength) Polystyrene 2‐Butanone
Also consider: • Process‐induced changes • Hazards related to unconventional forms
(Post‐)Process Hazards
Ergonomic Noise Shock
Fall/Impact Burns Fire/Explosion
Altered Compressed Materials & Laser/Radiation Gases Byproducts
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Work Environment
Transport
Storage
Contamination
Scheduling / Stress
AM Hazard Questions
Material‐ Is this material toxic? If yes, how? related Is this material reactive? If yes, how?
What are the likely exposure routes?
Process‐ What hazards originate from the material‐binding process? related What hazards originate from post processes?
What worker activities are necessary to support the process?
Environment‐ How are materials/parts moved in/out/around the workspace? related How and where are materials/parts stored?
How are the workspace and worker activities organized?
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Example: Metal SLS
Material‐ Al is eye/skin/respiratory irritant; Ni, CoCr alloys are sensitizers… related Al, Ti powders are reducing, potentially flammable/explosive…
Powders are easily inhaled, or dermally contacted…
Process‐ Laser exposure, compressed gases related Powder removal, final finishing/polishing
Loading powder, removing powder/products, maintenance
Environment‐ Designated pathways, carts, etc… related Designate storage rooms, workspaces, etc…
Workspace isolation, worker scheduling
Example Hazards
Material Vat Powder Bed Binder Jetting Extrusion Polymerization Fusion
Material Toxicity Material Toxicity Material Toxicity Material Toxicity
Powder Powder FP/UFP Emissions VOC Emissions Inhalation/Contact Inhalation/Contact
VOC Emissions Fires Explosion VOC Emissions
Post‐Process Post‐Process Post‐Process Burns Spills Exposure Exposure
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AM SAFETY CULTURE (OPPORTUNITIES)
Our Challenge: Agility
Product We don’t The tool designers know users want to everything don’t, move fast. we need. either!
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AM users and knowledge will vary
Users may differ in terms of …
• Budget for OSH activities (controls) Large Enterprises Small‐to‐Medium Service Locations • Expertise (in both OSH and additive Enterprise manufacturing) • Synergistic exposures • Communication preferences • Decision‐making structure •Safety culture Hospitals Schools Libraries • Demographics
Collaboration is Necessary
Tool Designers Health & Safety Experts
Product Designers
Product Tool User Operators
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SUMMARY
Additive Manufacturing …
Is substantially impacting multiple market sectors
Includes many materials and processes
Hazards will vary significantly based on particulars
Paradigm shift brings risk and opportunity
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NIOSH Performs On‐Site Research
• Over 100 visits (65 sites)
• Uses existing methods
• Evaluate processes & personal exposures
• Provide Guidance and recommendations
• Seeking more partnerships and collaborations!
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References & Image Sources
• 3D Maker Noob. Youtube. URL: https://www.youtube.com/watch?v=xDUWcQuj7VU accessed 8‐Feb‐2017). • 3D Printer Overview Setting. TEVO Little Monster Delta 3D Printer DIY Kit ‐ 220V BLACK+EU PLUG. YouTube. URL: https://youtu.be/yecdrA6upo4 (accessed 9 Feb 2018). • 3D Printing Industry (2016) The Free Beginner’s Guide. URL: https://3dprintingindustry.com/3d‐printing‐basics‐free‐beginners‐guide/processes/ (accessed 19‐Oct‐2016). • 3D Printing Taps 4th Industrial Revolution; HP Discusses Big Ambitions. Investor’s Business Daily. URL https://www.investors.com/research/industry‐snapshot/hp‐inc‐says‐3d‐printing‐ will‐bolster‐4th‐industrial‐revolution/ (accessed 8 Feb 2018). • Balch, Oliver (2017). Building by numbers: how 3D printing is shaking up the construction industry. The Guardian. URL: https://www.theguardian.com/sustainable‐ business/2017/jan/31/building‐by‐numbers‐how‐3d‐printing‐is‐shaking‐up‐the‐construction‐industry • Bloomington Public Schools (2014) Poplar Bridge Elementary to incorporate 3D printing. URL: https://www.bloomington.k12.mn.us/node/3121478 (accessed 20‐Nov‐2017). • Florida Public Library (2017) Our 3D Printer. http://www.floridapubliclibrary.org/news/our‐3d‐printer/ (accessed 20‐Nov‐2017). • GE Additive (2017a) GE Additive takes bold moves in aerospace industry. https://www.ge.com/additive/press‐releases/ge‐additive‐takes‐bold‐moves‐aerospace‐industry (accessed 20‐ Nov‐2017). • GE Additive (2017b) GE Additive to certify new production partners. https://www.ge.com/additive/press‐releases/ge‐additive‐certify‐new‐production‐partners (accessed 20‐Nov‐2017). • Balch, Oliver (2017). Building by numbers: how 3D printing is shaking up the construction industry. The Guardian. URL: https://www.theguardian.com/sustainable‐ business/2017/jan/31/building‐by‐numbers‐how‐3d‐printing‐is‐shaking‐up‐the‐construction‐industry • Hamermesh, Daniel; Ebeling, Mick; Nordt, Alison; Allen, Nick; Hultgren, Kacie; Heemsbergen, Luke (2014). Will 3‐D Printers Change the World? The New York Times. https://www.nytimes.com/roomfordebate/2014/08/11/will‐3‐d‐printers‐change‐the‐world (accessed 8 Feb 2018). • Hewitt, Cooper (2014). Design Dictionary: Powder Bed 3D Printing. Youtube. URL: https://youtu.be/kBHsfNDsbCs (accessed 8‐Feb‐2017). • Materialgeeza (2008) SLS system schematic. URL: https://en.wikipedia.org/wiki/File:Selective_laser_melting_system_schematic.jpg (accessed 9‐Jun‐2016). • Materialgeeza (2013) Stereolithograthy apparatus schematic (vector version made with Inkscape). URL: https://commons.wikimedia.org/wiki/File:Stereolithography_apparatus_vector.svg (accessed 19‐Oct‐2016). • McCue, TJ. (2016) Wohlers Report 2016: 3D Printing Industry Surpassed $5.1 Billion. Forbes. URL: http://www.forbes.com/sites/tjmccue/2016/04/25/wohlers‐report‐2016‐3d‐printer‐ industry‐surpassed‐5‐1‐billion/#45ea84777cb1 (accessed 18‐Oct‐2016). • O’Conner, Daniel (2013). Formlabs launch new Resin and win CES award. TCT Magazine. URL: https://www.tctmagazine.com/tct‐events/formlabs‐launch‐new‐resin‐and‐win‐ces‐award/ (accessed 13 Feb 2017). • Open Biomedical Initiative (2016) Japanese medical insurance to cover cost of 3D printed organ models. URL: http://www.openbiomedical.org/japanese‐medical‐insurance‐to‐cover‐ cost‐of‐3d‐printed‐organ‐models/ (accessed 20‐Nov‐2017). • Pesce, Mauizio (2015). 3D Printing Materials. Wikimedia Commons. URL: https://commons.wikimedia.org/wiki/File:3D_Printing_Materials_(16837486456).jpg (accessed 13 Feb 2017). • Porter, Lon (2014). 3D Print of an Extruder Cooling Fan Mount (8x speed w/o audio) . Youtube. URL: https://www.youtube.com/watch?v=eT‐wVqUijr4 (accessed 13‐Feb‐2017). • Sęk, Matylda (2011). Crosslinker, UV Stratalinker 2400. Wikimedia Commons. URL: https://commons.wikimedia.org/wiki/File:Crosslinker_UV_Stratalinker_2400‐1.jpg (accessed 13 Feb 2017). • Sols Systems (2016) Mapp3D. http://www.sols.com/mapp3d/ (accessed 20‐Nov‐2017). • Spiritdude (2012) Fused filament fabrication. URL: http://reprap.org/wiki/File:FFF.png (accessed 19‐Oct‐2016). • United States Government Accountability Office (2015) 3D Printing: Opportunities, Challenges, and Policy Implications of Additive Manufacturing. GAO‐15‐505SP. Deagon, Brian (2016). • Vít, Tomáš (2017). Selective Laser Sintering (or LaserCUSING) cycle. Youtube. URL: https://youtu.be/5‐y8iep7jTk (accessed 8‐Feb‐2017).
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