Three-dimensional (3D) printing has introduced a paradigm shift in the manufacturing world, and it is increasing in popularity. In cases of such rapid and widespread acceptance of novel technologies, material or process safety issues may be underestimated, due to safety research being outpaced by the breakthroughs of innovation. However, a definitive approach in studying the various occupational or environmental risks of new technologies is a vital part of their sustainable application. In fused filament fabrication (FFF) 3D printing, the practicality and simplicity of the method are juxtaposed by ultrafine particle (UFP) and volatile organic compound (VOC) emission hazards. In this work, the decision of selecting the optimal material for the mass production of a microfluidic device substrate via FFF 3D printing is supported by an emission/exposure assessment. Three candidate prototype materials are evaluated in terms of their comparative emission potential. The impact of nozzle temperature settings, as well as the microfluidic device’s structural characteristics regarding the magnitude of emissions, is evaluated. The projected exposure of the employees operating the 3D printer is determined. The concept behind this series of experiments is proposed as a methodology to generate an additional set of decision-support decision-making criteria for FFF 3D printing production cases.

The COVID-19 pandemic instigated massive production of critical medical supplies and personal protective equipment. Injection moulding (IM) is considered the most prominent thermoplastic part manufacturing technique, offering the use of a large variety of feedstocks and rapid production capacity. Within the context of the European Commission-funded imPURE project, the benefits of IM have been exploited in repurposed IM lines to accommodate the use of nanocomposites and introduce the unique properties of nanomaterials. However, these amendments in the manufacturing lines highlighted the need for targeted and thorough occupational risk analysis due to the potential exposure of workers to airborne nanomaterials and fumes, as well as the introduction of additional occupational hazards. In this work, a safety-oriented failure mode and effects analysis (FMEA) was implemented to evaluate the main hazards in repurposed IM lines using acrylonitrile butadiene styrene (ABS) matrix and silver nanoparticles (AgNPs) as additives. Twenty-eight failure modes were identified, with the upper quartile including the seven failure modes presenting the highest risk priority numbers (RPN), signifying a need for immediate control action. Additionally, a nanosafety control-banding tool allowed hazard classification and the identification of control actions required for mitigation of occupation risks due to the released airborne silver nanoparticles.

Fused Filament Fabrication (FFF) has been established as a widely practiced Additive Manufacturing technique, using various thermoplastic filaments. Carbon fibre (CF) additives enhance mechanical properties of the materials. The main operational hazard of the FFF technique explored in the literature is the emission of Ultrafine Particles and Volatile Organic Compounds. Exposure data regarding novel materials and larger scale operations is, however, still lacking. In this work, a thorough exposure assessment measurement campaign is presented for a workplace applying FFF 3D printing in various setups (four different commercial devices, including a modified commercial printer) and applying various materials (polylactic acid, thermoplastic polyurethane, copolyamide, polyethylene terephthalate glycol) and CF-reinforced thermoplastics (thermoplastic polyurethane, polylactic acid, polyamide). Portable exposure assessment instruments are employed, based on an established methodology, to study the airborne particle exposure potential of each process setup. The results revealed a distinct exposure profile for each process, necessitating a different safety approach per setup. Crucially, high potential for exposure is detected in processes with two printers working simultaneously. An updated engineering control scheme is applied to control exposures for the modified commercial printer. The establishment of a flexible safety system is vital for workplaces that apply FFF 3D printing.

Extensive research is currently being conducted on nanotechnologies worldwide, and the applications of nanomaterials are continuously expanding. Given their unique intrinsic characteristics, such as their small size and increased reactivity, nanomaterials may pose an occupational, environmental or consumer hazard. Therefore, a highly important aspect of ensuring the sustainable use of nanotechnologies is the establishment of proper health and safety practices. The area of nanosafety research has produced significant outcomes the last decades, and many of these achievements have been reflected in the standardization field. In this work, a discussion of prominent nanosafety standards (ISO/TS 12901-2:2014 and ISO/TR 12885:2018) is presented, based on the barriers faced during the endeavor to apply their principles within a research context. A critical viewpoint regarding their application is presented, and gaps faced in adapting the standards to the materials and processes applied are noted. Additionally, approaches that were followed to circumvent these gaps are also highlighted as suggestions to potentially overcome these barriers in future standardization efforts.