3D Printing: General Overview and the Hazards Associated with Them

Objectives Brief history of 3D printing Types of 3D printing technology Materials Associated with 3D printing Hazards Associated with 3D printing Management of Waste

Facts about Virginia Tech Main campus located in Blacksburg, VA 31,000 full-time students (83% undergrad, 17% graduate) Main campus consists of 2,600 acres and 135 buildings Over 10,000 salaried faculty and staff members

Quick Background 3D Printing encompasses several different technologies Opposite of “traditional” manufacturing Additive instead of Subtractive More cost effective and efficient Small units start at $1000 Uses less energy and materials than traditional manufacturing

How 3D Printing Works…Generally Items to be manufactured are scanned Models are “sliced” into many layers Scanning using 3D scanners File preparation, so printer can read the image Printer layers process materials Materials include plastics, ceramics, metals, sugars and other bio materials

Types of 3D Printing Sterolithography 1st 3D process and most commercialized Many types of support material including: ABS PLA Curing is needed http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

Types of 3D Printing Digital Light Processing (DLP) Similar to SL-uses photopolymers Uses an arc light, not a UV laser Uses shallower vat-decreases waste Faster manufacturing time Curing is also needed

Types of 3D Printing Laser Sintering/Laser Melting Uses Powered Materials Laser fuses the material and forms a solid More material is added after each layer Laser fuses the new layer to the previous Metal Sintering=higher powered laser & temperatures http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

DTM Sinterstation 2500 Plus Types of 3D Printing DTM Sinterstation 2500 Plus

Types of 3D Printing Extrusion/FDM/FFF Most Common Melts plastic filament through an extruder ABS and PLA are most common http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

Types of 3D Printing MarkerBot Replicator 2

Types of 3D Printing Fortus 250mc

Stratasys Dimension Elite Types of 3D Printing Stratasys Dimension Elite

Types of 3D Printing Inkjet: Binder Jetting Binder sprayed into a powder Wide range of materials, including food and ceramic http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

Zcorp z510 Types of 3D Printing http://www.me.vt.edu/dreams/binder-jetting/

ExOne R2 Types of 3D Printing Metals and ceramics http://www.me.vt.edu/dreams/binder-jetting/

Types of 3D Printing Inkjet: Material Jetting Molten material, usually photopolymers Jetted through multiple heads Cured via UV light Multiple materials used to make single part http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

Types of 3D Printing Objet Connex 350

Types of 3D Printing Selective Deposition Lamination (SDL) Layers and cuts one layer of copy paper at a time http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

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Types of 3D Printing Electron Beam Melting Very similar to Laser Sintering Uses electron beam instead of a laser Vacuum conditions http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/processes/

3D Printing Materials Plastics Nylon/Polyamide-used in both sintering or FDM. Aluminum powders can be combined to make Alumide Acrylonitrile butadiene styrene (ABS)-widely used on entry-level FDM printers. Typically filament Polylactic Acid- biodegradable, can be used in DLP/SL and FDM. Wood/Polymer composite(WPC)-”LayWood” specially developed for extrusion processes

3D Printing Materials Metal Powders Aluminum & Cobalt-most common Stainless steel -typically used sintering/melting/EBM Gold & Silver- Jewelry sector Uncured Polymer Powders Most uncured resins- irritants, especially through inhalation Nuisance dust issues Aerosolization

3D Printing Materials Biological Materials Known as “bioprinting”- generating tissues such as skin, bone, blood vessels. Working organs??? Drug printing possibilities Food Chocolate and Sugar-main media for 3D printing http://www.smithsonianmag.com/innovation/soon-doctor-print-human-organ-on-demand-180954951/?no-ist

3D Printing Hazards Ultra-Fine Particles (UFP) 2013 study looked at desktop printers using molten polymer disposition First major research looking into ultrafine particles from 3D printing Looked at 2 PLA printers and 3 ABS printers in a 45m3 furnished office. ABS printers operated at higher extruder and baseplate temps than the PLA printers

3D Printing Hazards Stephens, B., Azimi, P., El Orch, Z., & Ramos, T. (2013). Ultrafine particle emissions from desktop 3D printers. Atmospheric Environment, 79, 334-339. doi:10.1016/j.atmosenv.2013.06.050

3D Printing Hazards Background taken for 30 minutes. The PLA printers operated for about 30minutes then were shut off. All 5 printers began running similantiously.

3D Printing Hazards Support Material Solvents Propanol, D-Limonene Sodium Hydroxide/Potassium Hydroxide Common items used in labs Offices with desktop printing Build your Own designs??? Many plans on the Internet Proper safety precautions utilized?

3D Printing Waste Issues VT is limited by local authority limited drain disposal limited solid waste disposal

3D Printing Waste Issues Support Material Solvents Propanol, D-Limonene Sodium Hydroxide/Potassium Hydroxide Other Cleaning Materials Ethylene Glycol Monobutyl Ether-FP 144°F

3D Printing Waste Issues Isobornyl acrylate- Phosphoric Acid-

3D Printing Waste Issues Metal Powers Copper Oxide, Stainless Steel powders, Tungsten carbide- Aluminum - Plastic Polymers & Inks Recycling options for plastics- Some inks contain Benzene, Xylene, Carbon Black

3D Printing Summary Great Tools Becoming More Accessible, By Cost or Build You Own Wide Variety of Build Materials =Variety of Possible Waste Issues More Research on Potential Hazards Good Ventilation is a Must Make Sure Clients Understand Chemicals State/Local Restrictions=Limits Waste Disposal Options