groth--additive manufacturing 2018-03-14f · • united states government accountability office...

Additive Manufacturing: Methods, Hazards, and Safety Culture

2/15/2018

Gary Roth, MS, PhD 1


Gary Roth, MS, PhDHealth Scientist / Associate Service Fellow

2018 Indiana Safety and Health Conference & ExpoIndianapolis, IN14 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.


2/15/2018


Market Impact of AM/3DP

Aerospace Automotive Electronics Consumer Medical


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Comparative Advantages

• Established

• More material options

• Consistent quality

• Higher throughput

Traditional

• Minimal waste material

• Complex features

• Fewer tools

• Processes easily modified

Additive

Benefits of AM/3DP

•Computer‐Aided Design (CAD)

•Rapid iteration

•More innovation spaceDevelopment

•Novel geometries

•More complex parts

•Efficiently use high‐cost materials

•Customization

Products

•Lower material use

•Fewer tools

•Just‐in‐Time fulfillment

•Distributed manufacturing

Logistics


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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

Additive

Man

ufacturing Liquid Feedstock

Vat PolymerizationStereolithography

Digital Light ProcessingMaterial Jetting

Solid FeedstockMaterial Extrusion Fused‐Filament

Fabrication

Sheet Lamination

Powdered FeedstockPowder‐Bed Fusion

Selective Laser Sintering / Melting

Electron Beam Melting

Selective Heat SinteringBinder Jetting


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Material Extrusion

• Thermoplastic

Build Material

• Solid filament

Feedstock Form

• Deposition nozzle

Selector

• Melting

Binding Mechanism

Powder Bed Fusion

• Metal/Plastic/Ceramic

Build Material

• Powdered

Feedstock Form

• Laser

Selector

• Sintering / Melting

Binding Mechanism


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Vat Polymerization

• Photopolymer resin

Build Material

• Liquid

Feedstock Form

• UV Laser/Projector

Selector

• Curing

Binding Mechanism

Binder Jetting

• Metal/Plastic/Ceramic

Build Material

• Powdered

Feedstock Form

• Printer Head

Selector

• Adhesion/cementing

Binding Mechanism


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AM WORKER HAZARDS

Holistic Perspective

Materials

EnvironmentProcess


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Materials

Polymers

Acrylonitrile‐butadiene‐styrene

Polylactic acid

Propylene fumarate

Poly(vinyl alcohol)

Polycarbonate

Polyethylene

Polystyrene

Solvents

Dimethyl fumarate

Isopropanol

Acetone

Methyl Ethyl Ketone

2‐Butanone

Metals

Ti‐6Al‐4V

IN 625 & IN 718 (Ni, Cr)

17‐4 PH stainless steel

Cobalt chromium

Nanomaterials

nFe (steel sintering)

nAg (sintering, conductivity)

nCB, CNT (conductivity, stiffness, tensile strength)

nSiOx (polymer strength)

Also consider:• Process‐induced changes• Hazards related to unconventional forms

(Post‐)Process Hazards

Ergonomic Noise Shock

Fall/Impact Burns Fire/Explosion

Altered Materials & Byproducts

Compressed Gases

Laser/Radiation


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Work Environment

Transport

Storage

Contamination

Scheduling / Stress

AM Hazard Questions

Material‐related

Is this material toxic? If yes, how?

Is this material reactive? If yes, how?

What are the likely exposure routes?

Process‐related

What hazards originate from the material‐binding process?

What hazards originate from post processes?

What worker activities are necessary to support the process?

Environment‐related

How are materials/parts moved in/out/around the workspace?

How and where are materials/parts stored?

How are the workspace and worker activities organized?


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Example: Metal SLS

Material‐related

Al is eye/skin/respiratory irritant; Ni, CoCr alloys are sensitizers…

Al, Ti powders are reducing, potentially flammable/explosive…

Powders are easily inhaled, or dermally contacted…

Process‐related

Laser exposure, compressed gases

Powder removal, final finishing/polishing

Loading powder, removing powder/products, maintenance

Environment‐related

Designated pathways, carts, etc…

Designate storage rooms, workspaces, etc…

Workspace isolation, worker scheduling

Example Hazards

Material ExtrusionMaterial Extrusion

Material Toxicity

FP/UFP Emissions

VOC Emissions

Post‐Process Burns

Vat Polymerization

Vat Polymerization

Material Toxicity

VOC Emissions

Fires

Spills

Powder Bed Fusion

Powder Bed Fusion

Material Toxicity

Powder Inhalation/Contact

Explosion

Post‐Process Exposure

Binder JettingBinder Jetting

Material Toxicity

Powder Inhalation/Contact

VOC Emissions

Post‐Process Exposure


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AM SAFETY CULTURE (OPPORTUNITIES)

Our Challenge: Agility

Product designers want to

move fast.

We don’t know

everything we need.

The tool users don’t, either!


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AM users and knowledge will vary

Large Enterprises Small‐to‐Medium Enterprise

Service Locations

Hospitals Schools Libraries

• Budget for OSH activities (controls)

• Expertise (in both OSH and additive manufacturing)

• Synergistic exposures

• Communication preferences

• Decision‐making structure

• Safety culture

• Demographics

Users may differ in terms of …

Product Designers

Tool Designers

Tool Operators

Product User

Collaboration is Necessary

Health & Safety Experts


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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!

[email protected]


2/15/2018


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groth--additive manufacturing 2018-03-14f · • united states government accountability office...

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