Characterization of emissions generated during additive manufacturing of polymer parts by the fused deposition modeling technique

Additive manufacturing has developed steadily since it was first introduced in the 1980s, but it is not without occupational risks. The main objectives of this study were to characterize airborne particle and VOC (Volatile Organic Compounds) emissions generated by a 3D additive manufacturing using polymers and to evaluate the effectiveness of local extraction ventilation as a control measure to reduce emissions. A comprehensive measurement methodology involving direct-reading instruments and active tube air sampling was deployed around and inside the machine. Three polymer materials were studied: ABS (Acrylonitrile Butadiene Styrene), ASA (Acrylonitrile Styrene Acrylate), and PETG (PolyEthylene Terephthalate Glycol). The same test part was fully manufactured three times with each material. During manufacturing, particle number concentrations and real-time VOC profiles, particularly focusing on styrene, were measured simultaneously. The extraction ventilation parameters on the Zortrax M300 3D printer were recorded and analyzed to assess how they affected pollutant containment and prevention of operator exposure. The number of particles measured for the various materials and their concentration suggest possible operator exposure to airborne particles. Total VOC concentration values were measured from ABS (432.8 µg/m³), ASA (124.1 µg/m³), and PETG (4.7 µg/m³). Real-time monitoring was done for styrene emissions during the manufacturing cycles for the three different materials tested, coupled with VOCs sampling on adsorbent tubes. Use of a local exhaust ventilation system reduced the airborne concentrations between 95% and 99%. It is therefore recommended that 3D printers be placed under an extraction system.