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Research on the health and safety concerns of 3D printing is new and in development due to the recent proliferation of 3D printing devices. A National Institute for Occupational Safety and Health (NIOSH) study noted particle emissions from a 3D printer peaked a few minutes after printing started and returned to baseline levels 100 minutes after printing ended. Emissions from 3D printers can include a large number of ultrafine particles, and volatile organic compounds (VOCs).

The toxicity from emissions varies by source material due to differences in size, chemical properties, and quantity of emitted particles. Excessive exposure to VOCs can lead to irritation of the eyes, nose, and throat, headache, loss of coordination, and nausea and some of the chemical emissions of 3D printers have also been linked to asthma. Based on animal studies, carbon nanotubes and carbon nanofibers sometimes used in 3D printing can cause pulmonary effects including inflammation, granulomas, and pulmonary fibrosis when at the nanoparticle size.

Carbon nanoparticle emissions raise the concern of dust explosions. Processes using powder metals, which are reactive and highly combustible, also pose a fire threat. At least one case of severe injury was noted from an explosion involved in metal powders used for 3D printing. Other general health and safety concerns include the hot surface of UV lamps and print head blocks, high voltage, ultraviolet radiation from UV lamps, and potential for mechanical injury from moving parts.

Hazard controls
Techniques and methods for controlling exposure to 3D printing hazards help ensure the safety of workers. The hierarchy of hazard controls outlines methods of control in order of effectiveness. Elimination and substitution are identified as the most effective controls, followed by engineering and administrative controls, and then the least effective control, personal protective equipment.

Although elimination and substitution are the most desirable controls, 3D printed products often require the use of specific materials which bring with them specific hazards. If the printed product does not require a specific material, avoiding those that release volatile organic compounds and ultrafine particles is an effective method of reducing the exposure to potentially harmful emissions. Another way to eliminate the hazard is to keep workers away from the printer.

Engineering and administrative controls concerning nanoparticles, and the handling of dusts and powders have been developed by government agencies, and health organizations. Exposure to emissions can be reduced by using manufacturer-supplied equipment and proper ventilation. Procedural techniques to reduce exposure include turning off the printer if it is jammed and then allowing it to ventilate before removing the cover, and maintaining a distance away from the printer.

The least desirable control method is the use of personal protective equipment. This is used in case the other methods are not effective enough to completely eliminate the hazard. In the case of 3D printers, respirators can be used to provide further protection from emissions.

Exposure assessment
Methods used for exposure assessment risk have been developed based on existing protocols for nanoparticle exposure assessment. Although no occupational exposure limits specific to 3D printer emissions exist, certain source materials used in 3D printing, such as carbon nanofiber and carbon nanotubes, have established occupational exposure limits at the nanoparticle size.