1. 3D Printing: General Overview and the Hazards Associated with Them

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

3. 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

4. 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

5. 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

6. Types of 3D Printing Sterolithography
1st 3D process and most commercialized
Many types of support material including:
ABS
PLA
Curing is needed

7. 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

8. 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

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

10. Types of 3D Printing Extrusion/FDM/FFF Most Common
Melts plastic filament through an extruder
ABS and PLA are most common

11. Types of 3D Printing
MarkerBot Replicator 2

12. Types of 3D Printing
Fortus 250mc

13. Stratasys Dimension Elite
Types of 3D Printing
Stratasys Dimension Elite

14. Types of 3D Printing Inkjet: Binder Jetting
Binder sprayed into a powder
Wide range of materials, including food and ceramic

15. Zcorp z510 Types of 3D Printing

16. ExOne R2 Types of 3D Printing
Metals and ceramics

17. 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

18. Types of 3D Printing
Objet Connex 350

19. Types of 3D Printing Selective Deposition Lamination (SDL)
Layers and cuts one layer of copy paper at a time

21. Types of 3D Printing Electron Beam Melting
Very similar to Laser Sintering
Uses electron beam instead of a laser
Vacuum conditions

22. 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

23. 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

24. 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

25. 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

26. 3D Printing Hazards
Stephens, B., Azimi, P., El Orch, Z., & Ramos, T. (2013). Ultrafine particle emissions from desktop 3D printers. Atmospheric Environment, 79, doi: /j.atmosenv

27. 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.

28. 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?

29. 3D Printing Waste Issues
VT is limited by local authority limited drain disposal limited solid waste disposal

30. 3D Printing Waste Issues
Support Material Solvents Propanol, D-Limonene Sodium Hydroxide/Potassium Hydroxide Other Cleaning Materials Ethylene Glycol Monobutyl Ether-FP 144°F

31. 3D Printing Waste Issues
Isobornyl acrylate- Phosphoric Acid-

32. 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

33. 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