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3D Metal Printing: Safety Challenges and Mitigation
April 6, 2017
John A. Slotwinski, Ph.D.
Additive Manufacturing Lead and Section SupervisorResearch and Exploratory Development Department
Johns Hopkins University Applied Physics Laboratory
Associate Research ProfessorDepartment of Materials Science and Engineering
Johns Hopkins University
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At APL We Take AM Safety Very Seriously…
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Outline
What is metal AM/3DP?What are the related hazards
and how do we mitigate them?What are the current safety
industry practices and standardization efforts? What are the lessons learned?
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Additive Manufacturing Center of Excellence
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Additive Manufacturing (aka 3DPrinting)
ASTM International: A process of joining materials to make objects from 3D model data, usually layer upon layer, as
opposed to subtractive manufacturing methodologies.
Synonyms: additive fabrication, additive processes, additive
techniques, additive layer manufacturing, layer
manufacturing, and freeform fabrication.
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Metal Laser Powder Bed Fusion
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What Are The Safety Hazards?
Fine Metal Powders Combustion Inhalation Skin Irritation Storage
Filtered Flammable Condensate High Power Laser Pressurized Inert Gasses and Oxygen
Displacement
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Metal AM Powders: The Basics
Types: Class A (Steels, Inconels, Cobalt Chrome,
Hastelloy) Class B (Aluminum, Titanium)
Produced primarily by Gas Atomization, provided by OEM or Third Parties
Generally spherical, diameters 10 m – 80 m
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Metal Powders: Safety
Hazards: Combustion Respiratory Skin Irritant Note: Powders generally not toxic
nor carcinogenic Mitigation:
Measurements Maintenance PPE Staying grounded Sparkless Tools Wet Separators to prevent powder
clouds Administrative
– Signage, training, approved operators only
Storage Note: Contrary to public
perception powders are generally contained!
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Other Hazards
Metal Condensate in Filters Class 4 Laser Inert Gasses
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Waste Disposal
Wet separator liquid waste Filters with solid condensate Trash
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The Things You Hope You Never Use…
Residue-free ABC extinguisher Class D fire extinguisher for metal
powder fires Eye Wash Gas exhaust system
In reality, the circumstances that would require these would be
extraordinary.
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AM Industry Safety Practice
There are no specific industry standards for metal AM.
Industrial safety implementation for metal AM runs the spectrum, from too much safety to not nearly enough.
Some previous metal powder standards are being applied, with good faith, but sometimes poor results.
Stay tuned, ASTM F42 is now developing AM safety standards.
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Conclusions and Lessons Learned
There are significant safety issues for metal powder AM but they are solvable
The first step to implementing metal AM, become friends with the organization’s safety officer
Be a jerk proactive about safety Safety is everyone’s responsibility With a new technology you sometimes have to make
judgment calls that are grounded in reasonableness
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Questions?
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