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UL and the UL logo are trademarks of UL LLC © 2016
Safety in Additive ManufacturingMetalsAre you prepared?August 2017
Paul Bates
TO PROMOTE SAFE WORK AND LIVING ENVIRONMENTS FOR ALL PEOPLE
World’s leading electrical safety testing and certification company• Over 12,000 employees
Leading safety brand• 22 billion UL Marks on products• 100,000 products tested annually
Worldwide presence• Over 70,000 customers in 104
countries• 131 labs and certification facilities in
39 countries2
2014 Occupational Health & Safety Administration Additive Manufacturing Citation
“The employer did not furnish employment and a place of employment which
were free from recognized hazards that were causing or likely to cause
death or serious physical harm, in that employees were exposed to fire
& explosion hazards from combustible dust and from hydrogen
gas while working with a 3D printing equipment system in an
additive manufacturing facility that fabricated items from combustible
metal alloy powders containing titanium, aluminum and other combustible
metals…”
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Facilities have safety risks at each layer of the additive manufacturing infrastructure
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Layers of Protection
Equipment
Facility
Material
Safety Risks
Combustibility Instability ReactivityToxicity
Identifying the individual risks & their interactions is critical to properly managing the safety of an AM facility
AM powders are hazardous materials that exhibit all of the safety risks
Aluminum Powder ExplosionHuntington Indiana | Oct 2003
The U.S. Chemical Safety Board (CSB)
identified 281 dust incidents from 1980 to
2005:
§ 119 worker deaths and 718 injuries
§ 10 dust explosions per year with 71%
having fatalities
§ Property losses averaging over $1M per
incident
Metal and plastic powder accounted for
34% of all incidents
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Equipment
Facility
Material
Material hazard identification & management is increasingly important
Toxicity
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Causes of Fire & Explosion
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Equipment
Facility
Material
ü AM processes generate fine & ultra-
fine particles that may cause
respiratory diseases
ü AM resins are toxic, irritants,
desensitizers & highly combustible
ü Filaments may have toxic additives
& are combustible
Filaments & resins also contain similar safety risks
Material hazard identification & management is increasingly important
Suffocation hazard from inert gas atmosphere
Detonation/ deflagration hazard from materials
Thermal hazard from lasers
Laser radiation hazard from lasers
Shock hazard from high voltage requirements
Pinching & crushing hazards from build platform
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Equipment
Facility
Material
AM machines have a variety of functional safety risks
AM equipment may need to comply with regulations on hazardous locations (dependent on safety management systems implemented)
ATEX Directive
Portaria179
Powder Cloud
Powder Layers
Electrostatic Charge
Powder Cloud
Equipment Lacks HAZLOC Certification
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Equipment
Facility
Material
Materials and equipment interact to significantly increase safety risks
Understanding of AM facility safety risk is limited across the industry
Adopters have limited awareness of the AM technology risks & the governing regulations
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Governing Regulations in the U.S.*
*Similar requirements exist in EU and APAC regions
§ OSH Act of 1970: General Duty Clause (5 (a)(1))§ 29 CFR 1910: Subpart H, 1910.119 & 1910.120
§ U.S. NFPA 484: Standard for Combustible Metals§ U.S. NFPA 652: Standard on the Fundamentals of
Combustible Dust
§ U.S. EPA Resource Conservation & Recovery Act of 1976
§ U.S. Department of Transportation - Hazardous Materials Transportation Act 49 CFR 100-185
Consequences of non-compliance include citations up to $500K, facility shutdowns & criminal charges
WHAT DOES ALL THIS MEAN TO US?
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• Inhalation• Skin Absorption• Ingestion• Injection
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PERSONAL SAFETY - CREATE A BARRIER
RESPIRATORS
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NOT YOUR AVERAGE GLOVES
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FACILITY SAFETY – PROCEDURES!
• Leak proof valves• Correct plumbing• Monitors
• Storage• Handling
• Floor coating• Shoes
• Disposal
• Maintenance• Risk of contamination• Risk of explosion
UL and the UL logo are trademarks of UL LLC ©
15
GAS
ESD
SUPPORT EQUIPMENT
POWDER
WASTE
GAS
• Leak proof valves• Correct plumbing• Monitors
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ESD
• Floor coating• Shoes
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SUPPORT EQUIPMENT
• Maintenance• Risk of contamination• Risk of explosion
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POWDER
• Storage• Handling
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WASTE
• Disposal
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SAFETY IS NOT AN OPTION
• Existing regulations apply and can bring civil or criminal penalties• OSH Act of 1970• OSHA 1970 Resource Conservation and Recovery Act (RCRA)• Code of Federal Regulations for Transportation of Hazardous Materials
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UL approach in managing facility safety risks & in conforming to regulations & industry standards
Advisory Testing Auditing
UL Services
Layers of Protection
Equipment
Facility
Material
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Combustibility Instability ReactivityToxicity
Safety Risks
