311 Lessons learned from R&D and industrial metal additive manufacturing

Metal additive manufacturing (AM), commonly known as 3D-printing, is an emerging state-of-the art technology with significant economic and practical advantages. Due to its relative short history, especially in industrial serial production, the knowledge regarding exposure and health risks is severely limited. To alleviate this, we have monitored the occupational exposure and potential health effects at both smaller R&D-sites and at large-scale AM/powder production facilities. Exposure was monitored through stationary and personal sampling of total and inhalable dust followed by metal analysis. Particle counting instruments were used to identify dusty works tasks and to evaluate preventive measures. AM operators and controls underwent health examinations, including questionnaires, spirometry, and blood and urine sampling to measure exposure and clinical health markers. Exposure during printing were generally low but other aspects of the production chain were of greater concern regarding exposure risks: production of metal powder feedstock, handling of metal powder before/after print, and post-printing processes. During three research projects, we have seen a shift from a dusty work environment to a more safe-by-design approach throughout the AM process. Despite the AM operator’s relatively low exposure to dust and metals, we identified changes in a urinary marker for kidney function. However, this finding needs to be further evaluated. In summary, our studies into the relative new field of metal AM exposure and health effects provides a basis to help companies and operators handling these techniques to move toward safe working conditions.