How 3D Printers are Finding a (Safe) Home in the Workplace

3D printers in the workplace are more commonplace than ever as industries turn to innovative solutions to improve product design and manufacturing. However, there are several risks to account for when operating this equipment. Here is how various sectors are utilizing this innovative tool for greater efficiency and managing those pain points.

Prototyping and Product Development

3D printing for prototyping and product development is rapidly expanding across architecture, medicine, aeronautics, automotive and more. The process enables the creation of complex designs into tangible models that conventional manufacturing cannot achieve. It also reduces human error during production.

For instance, the automotive industry may use 3D printing to prototype various instruments and handles. In the medical field, its application is revolutionizing custom bioresorbable scaffolds to overcome challenges with stents, such as insufficient sizes and designs. The rapid iteration of products allows for faster testing and modification to expedite development processes.

Manufacturing and Production

Once products undergo prototyping, 3D printers can help spearhead manufacturing and production affordably in a timely manner. Different printers are conducive to various production processes, such as selective laser sintering, which the engineering sector tends to use. With this method, the printer shines a laser light on powder, melting it into a granular plastic layer by layer. It then brushes the plastic onto a building platform and continues the process until there is a tangible product.

The aerospace industry uses 3D printer manufacturing to create, construct and repair components. Compared to conventional manufacturing, 3D printing develops more lightweight products with improved automated properties. The automotive sector also manufactures various car parts with 3D printers.

Tooling and Fixture Applications

Tooling and fixtures refer to instruments and jigs that aid in holding, positioning, and constructing parts in manufacturing. 3D printers create tools for injection molding, cutting, stamping and assemblage. Fixtures and jigs keep objects in place or guide actions during construction and disassembly.

Using 3D printers for tooling is more consistent than conventional approaches, decreasing the need for manual alterations and fast-tracking operations. For instance, Heineken reduced delivery time by 70% to 90% at its Seville plant when it used the Ultimaker S5 printers to design new, optimized parts. IME Automation also produced jigs, fixtures and end-of-arm tooling utilizing the printer.

Education and Training

The education and training sector has widely adopted 3D printers to enhance learning through physical modeling, experimentation and invention. Teachers might use the technology to produce replicas of ancient artifacts for elementary history curricula or 3D mathematical models for mathematics classes. 

In biological sciences, 3D printers help create organ models to help students comprehend difficult medical concepts and receive hands-on practice. These tools also build essential components for robotics, while architecture students may use 3D printing to prototype building sketches.

Overall, 3D printing promotes more interactive learning environments to enhance student engagement and understanding in the classroom. Most importantly, it could help encourage creative thinking and foster problem-solving skills for the future. 

4 Safety Concerns Associated With 3D Printers in the Workplace

Innovations in 3D printing are occurring rapidly. However, although 3D printers in the workplace are transforming industries, machine operators must be aware of the following four safety concerns.

1. Material Emissions

3D printing emits several toxins, posing numerous health risks to workers. For instance, 3D printing processes release particulate matter, gases and volatile organic compounds that are harmful when inhaled. Ultrafine particles measuring 1-100 nanometers may also settle in the respiratory tract and are more difficult to eradicate from the body.

Much of these emissions derive from the printer filament — a partially melted thermoplastic used to form the 3D object. Oftentimes, the filament comprises poly-lactic acid and acrylonitrile butadiene styrene from corn and petroleum processes, respectively. 

2. Thermal Hazards

The heating elements on a 3D printer — like the hotend or heated bed — can pose a significant fire hazard when temperature control becomes unmanageable. This occurrence may damage the printing equipment and start a fire.

3D printers may overheat when temperature sensors malfunction. Corroded heater cartridges and faulty wiring may also result in thermal runaway. Outdated or glitched software and firmware may increase this risk, as well. 

3. Mechanical Hazards

Mechanical hazards usually pertain to moving parts and sharp objects. For example, the extruder assembly — which heats up and expels filament — can burn someone if they touch it. The build platform and gantry system can also pinch while operating.

Likewise, cutting tools and support structures have sharp edges, increasing the risk of cuts and puncture wounds. The best way to protect oneself from mechanical-related injuries is to ensure the 3D printer has the proper guarding and safety interlocks.

4. Electrical Hazards

The risk of electrocution, short circuits and fires is heightened with 3D printers, particularly due to their use of high-voltage power and heated elements. Damaged power cords and wiring, poor insulation, and low-quality power supplies are the biggest culprits, which may cause overheating and sparks.

Using 3D printers with automatic shutdown features is safest. Conducting regular inspections and relying on a power supply that matches the manufacturer’s electrical requirements is equally important for safety.

Addressing 3D Printing Safety at Work

Implementing 3D printing at work requires businesses to address the primary safety concerns to protect employees. This means mitigating hazards and protecting anyone utilizing the machinery. The following tips are essential for safer use of 3D printers:

• Equip operators with personal protective gear.
• Provide comprehensive and ongoing safety training.
• Conduct a risk and hazard assessment, pinpoint potential safety problems, and design a response plan in case of an emergency.
• Select safer filaments using less hazardous materials over toxic ones.
• Limit printing to essential activities.
• Create 3D printing enclosures to prevent the spread of emissions.
• Apply safeguards to printing components to protect operators from hot surfaces and sharp objects.
• Operate printers in well-ventilated areas with robust exhaust systems.
• Install air purifiers with HEPA filters to reduce airborne particulate matter.
• Ensure proper supervision during all 3D printing operations.

Inspecting the equipment and providing regular maintenance ensures printers work correctly without posing safety risks. Other measures companies can take are to ensure there are working fire extinguishers near the printers and visible signage detailing emergency procedures. Updating safety plans regularly is equally important to mitigate and prevent dangers.

Safe 3D Printing Cultivates Workplace Innovation

3D printing will continue transforming the workplace for the better. With each development in the process, sectors can streamline production and create better products. However, innovation does not negate safety. Enterprises must ensure the proper use of 3D printers in the workplace, and develop essential safety measures to protect employees from harm.