Prevention through design: insights from computational fluid dynamics modeling to predict exposure to ultrafine particles from 3D printing

Fused filament fabrication (FFF) 3D printers are increasingly used in industrial, academic, military, and residential sectors, yet their emissions and associated user exposure scenarios are not fully described. Characterization of potential user exposure and environmental releases requires robust investigation. During operation, common FFF 3D printers emit varying amounts of ultrafine particles (UFPs) depending upon feedstock material and operation procedures. Volatile organic compounds associated with these emissions exhibit distinct odors; however, the UFP portion is largely imperceptible by humans. This investigation presents straightforward computational modeling as well as experimental validation to provide actionable insights for the proactive design of lower exposure spaces where 3D printers may be used. Specifically, data suggest that forced clean airflows may create lower exposure spaces, and that computational modeling might be employed to predict these spaces with reasonable accuracy to assist with room design. The configuration and positioning of room air ventilation diffusers may be a key factor in identifying lower exposure spaces. A workflow of measuring emissions during a printing process in an ANSI/CAN/UL 2904 environmental chamber was used to provide data for computational fluid dynamics (CFD) modeling of a 6 m(2) room. Measurements of the particle concentrations in a Class 1000 clean room of identical geometry were found to pass the Hanna test for agreement between model and experimental data, validating the findings.

Automated summary

Research on the emissions and user exposure scenarios of Fused Filament Fabrication (FFF) 3D printers reveals varying amounts of ultrafine particles (UFPs) and volatile organic compounds emitted during operation. Computational modeling and experimental validation provide actionable insights for designing lower exposure spaces, with forced clean airflows and proper positioning of room air ventilation diffusers being key factors in identifying these spaces. Workshop measurements and CFD modeling in an environmental chamber demonstrate agreement between model and experimental data, validating the findings.