In Rapid Prototyping services, while highly efficient, several risks must be managed to ensure both personal and product safety.
Key Risks
Personal Safety Hazards:
High Temperatures & Burns: Technologies like FDM and SLA use hot nozzles, heated build plates, and UV lasers that can cause severe burns.
Toxic Fumes & Particles:
Melting plastics (like ABS) or curing resins can release harmful
volatile organic compounds (VOCs) and ultrafine particles into the air.
Mechanical Hazards: Moving parts in printers, such as gantries and tools, pose pinch-point and entanglement risks.
Chemical Exposure: SLA and Material Jetting use liquid resins and solvents that can be skin irritants or toxic.
Product Safety Risks:
Incorrect Data & Process Selection:
Using an unsuitable technology or incorrect file (e.g., non-manifold
STL files) leads to parts that fail or do not represent the final design
accurately.
Material Degradation: Improper storage of filaments or resins (exposure to moisture, light) results in weak, brittle, and unreliable parts.
Lack of Validation:
Without proper post-processing (e.g., curing, drying) and inspection,
parts may have hidden structural flaws or inaccurate dimensions.
Ensuring Safety
For Personal Safety:
Engineering Controls: Operate printers in well-ventilated areas or fume hoods. Use machines with enclosed build chambers.
Personal Protective Equipment (PPE): Mandate gloves, safety glasses, and sometimes lab coats when handling chemicals or raw materials.
Training & Procedures: Ensure operators are trained on all equipment and emergency procedures. Implement lockout/tagout for maintenance.
For Product Safety:
Process Standardization: Establish strict workflows for file preparation, machine calibration, and material handling.
Post-Processing Protocols: Follow manufacturer guidelines for cleaning, curing (for resins), and support removal to achieve intended material properties.
Quality Inspection:
Use tools like calipers, microscopes, and, for critical parts,
coordinate measuring machines (CMM) to verify dimensional accuracy and
quality.
By
systematically addressing these risks through engineering controls,
strict procedures, and thorough training, Rapid Prototyping services can
be both safe and reliable.
