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Mib neuralizer 3d print


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3D printing. What are we breathing?

Hello dear. In this article, I will try to tell you about what and in what quantities can be released from plastics during the FDM 3D printing process. The issue will be considered not from the side of global environmental pollution, but from the side of possible pollution of the room or workshop in which the FDM 3D printer directly operates.

I recommend that you read at least the fourth and fifth sections. Link to the video version of the article at the end. Here is the content of the article:

1 What and how much is released from plastics?

2 At what point in time is the emission of suspended particles maximum?

3 Effect of print settings

4 Particulate matter and VOC control methods

5 Pins

I must say right away that all the data is again for foreign plastics. In the comments, you write to me that it would be interesting to read about our materials, and not about foreign ones. Yes, I agree, perhaps the conclusions drawn from my work may not be applicable to "our" plastics. But in defense, I note that, firstly: the conditional foreign ABS should not radically differ from “our” ABS. Secondly, our major producers say that they buy raw materials from European firms. In this regard, I believe that the voiced data should be relevant for domestic filaments.

1 What and how much is released from plastics?

Two types of air pollutants are emitted from any plastic during operation of a 3D printer. Firstly, these are ultra- and finely dispersed (or suspended) particles, the size of which ranges from several nanometers to several micrometers. The second is volatile organic compounds.

In fact, the first group is micro dust, consisting of fragments of plastic, as well as fragments of fillers. In [1], an analysis was made of the release of suspended particles from various plastics during printing of a cylindrical sample with a duration of 60 minutes. Plastics PLA, PVA, ABS, PC, ASA, nylon were analyzed. An analysis of the results showed an interesting regularity in the intensity of the release of suspended particles during the operation of a 3D printer. Look at this graph:

Zero is the start of printing. It is clearly seen that it is at the very beginning of printing that there is a sharp increase in the concentration of suspended particles, then the concentration gradually decreases. The researchers attribute the initial peak to the nozzle's heating period to operating temperature. At this point, the plastic, which is motionless inside the nozzle, is subjected to prolonged heating and, consequently, thermal degradation. It can be seen from the graphs that such a picture is typical for absolutely all plastics. In support of this, the researchers from [2] come to similar conclusions.

Now let's look at each plastic separately. I think it will be most interesting for you to find out which plastics are leaders in terms of the number of emitted particles. ASA took first place, followed by nylon, PC and ABS, respectively. PLA and PVA turned out to be the most environmentally friendly.

This is how the size distribution of emitted particles looks like when printing a sample for pollution leaders:

And this is how the graphs for PLA of various companies and PVA look like:

The difference in the graphs is obvious. Please note that PLA and PVA emit particles at the very beginning of printing, and then, after a while, the release of particles almost stops.

Here are the results of measurements made by the authors of another study [3]:

On this graph, manufacturers and the type of plastic are labeled at the bottom, and the intensity of the release of suspended particles is measured along the vertical axis. Again, ABS and PC are among the leaders in terms of pollution. Additionally, HIPS and nylon joined them in this study. The most environmentally friendly again turned out to be PLA.

As far as carbon or fiberglass reinforced plastics are concerned, they are practically unexplored. In one of the works [4], along with other plastics, I was able to find this:

Underlined in red is PETG with 8-12% fiberglass. As you can see, such plastic is the leader in the selection of large particles. Once again I will say that this is the only result that I could find, so I can’t draw serious conclusions here, but anyway I decided to add it to the publication.

Now let's move on to the isolation of volatile organic compounds. In short, when printing with almost any filament, dozens of different compounds are released. Here, for example, is a table from [4]:

Plastics are signed in the table above. The first column lists the names of the chemical compounds. If there is no number for some connection, it means that it was not fixed by the device during printing with a specific plastic. Analyzing the table, we see that ASA and ABS plastics again become leaders in the anti-rating (ULTRAT is ABS with the addition of 3% polycarbonate). PETG becomes the most environmentally friendly (GLASS Transparent is also PETG, but with the addition of fiberglass).

Now let's turn to the results of research from another work [3], which examines a slightly different set of plastics:

This figure shows two histograms. The left histogram shows plastics with a maximum release of volatile organic compounds up to 40 micrograms per minute, and on the right - with an intensity of more than 40 micrograms per minute. The name of each column indicates the printer on which the material was printed.

Polycarbonate and TGlase (PETT plastic) are the most environmentally friendly. PLA looks a little worse. And nylon turned out to be the worst in terms of the number of emissions. It is interesting to note that for ABS plastics, the amount of emissions is highly dependent on the 3D printer on which they are printed, and can differ by as much as five times.

Pay attention to polycarbonate. If it is one of the most polluting in terms of the release of suspended particles, then it is the most environmentally friendly in terms of the release of volatile organic compounds.

2 At what point in time is the emission of suspended particles maximum?

Let's look at two graphs from [5]:

The left graph shows the particulate concentration inside the MakerBot 3D Printer, while the right graph shows the particulate concentration in the room where the 3D printer is located. Two peaks on the graphs mean two consecutively printed parts. Again, we see that a sharp increase in the number of suspended particles occurs at the very beginning of the printing of the part.

And here is another graph from another work [2]:

Shown here are three graphs showing the change in the concentration of suspended solids when printed with ABS plastic. According to the legend, the graphs differ in nozzle temperature. As in the previous work, it can also be seen here that after heating, at the moment of printing, an increase in the concentration of suspended particles occurs. From these graphs, another interesting point is visible.

3 Effect of print settings

These three graphs show that as the temperature of the nozzle increases, the concentration of suspended particles increases. However, the difference between the charts is significant. Other scientific works [4] confirm this:

This graph shows particulate matter concentration versus ABS nozzle temperature. It can be seen that at a nozzle temperature above 250 degrees there is a sharp increase in the number of ejected particles.

It is interesting to note the effect of printing speed on the concentration of suspended particles. Here is a graph from [2]:

These graphs show the dependence of the concentration of suspended particles when printing with ABS plastic at different print speeds. We compared printing at speeds of 30 mm/s (FR30 in the graph), 60 mm/s (FR60) and 90 mm/s (FR90). It is interesting to note that the maximum concentrations are observed at an average printing speed. In this case, the minimum concentration is observed for a speed of 90 mm/s.

4 Particulate matter and VOC control techniques

4.1 Studies have shown that reducing nozzle temperature reduces the amount of suspended particles released. Therefore, do not raise the nozzle temperature unnecessarily.

4.2 Increasing the print speed reduces the concentration of suspended particles. Another positive effect of increasing the printing speed is to reduce the printing time, which leads to a decrease in the time during which suspended particles are released.

4.3 Filtration. HEPA filters are effective for almost all sizes of particulate matter, but to be useful, you need a 3D printer with a closed chamber. In addition, HEPA filters do not capture volatile organic compounds at all, which, as it turns out, are emitted in abundance from some plastics. They need charcoal filters.

4.4 Ventilation or ventilation. I think this is the most efficient way for most conventional FDM 3D printers used at home and in workshops. Here are pictures from [5] showing the distribution of the concentration of suspended particles in a room with a 3D printer:

In a well-ventilated room, the concentration of particles is an order of magnitude lower and at a distance of more than a meter from the printer, only slightly higher than the background level.

4.5 Optimize printer performance. In paragraphs 4.1 and 4.2, I have already touched on the printing modes, but the authors of the scientific work [2] went further and proposed an interesting way to reduce the amount of suspended particles released. Its essence lies in the fact that we first heat up the empty nozzle to operating temperature, then load the filament and immediately start printing. After printing is completed, remove the filament. Here are graphs from [2] showing the result of such manipulations:

Both graphs show the emission of suspended particles when printing ABS with a nozzle temperature of 240°C and a speed of 60 mm/s. The top graph is printing without loading/unloading the filament.

5 Conclusions

As a conclusion, firstly, I would like to note that such plastics as ASA, ABS and nylon are leaders in terms of the amount of emitted particles and volatile organic compounds. The average highlights are polycarbonate and HIPS. The most environmentally friendly and in terms of suspended particles and volatile organic compounds are PLA and PETG.

Second, print in well-ventilated rooms or ventilate the room when printing. Try not to increase the temperature of the nozzle unnecessarily.

You may have noticed that I didn't say a word about how harmful it all is. The fact is that the assessment of the harmfulness of all this required quite a lot of time. I haven't been able to get definitive answers yet. Now I’ll just say that it’s rather harmful, especially with regular contact. Therefore, in this article, I deliberately did not touch on the topic of harmfulness. I hope that I will be able to deal with this issue to the end and then I will publish all the results.

Video version of the article:

That's all for now.

Sources:

1. Chýlek, R., Kudela, L., Pospíšil, J. , Šnajdárek, L. (2019). Fine particle emission during fused deposition modeling and thermogravimetric analysis for various filaments. Journal of Cleaner Production, 117790. doi:10.1016/j.jclepro.2019.117790

2. Deng, Y., Cao, S.-J., Chen, A., Guo, Y. (2016). The impact of manufacturing parameters on submicron particle emissions from a desktop 3D printer in the perspective of emission reduction. Building and Environment, 104, 311–319. doi:10.1016/j.buildenv.2016.05.02

3. Azimi, P., Zhao, D., Pouzet, C., Crain, N. E., Stephens, B. (2016). Emissions of Ultrafine Particles and Volatile Organic Compounds from Commercially Available Desktop Three-Dimensional Printers with Multiple Filaments. Environmental Science & Technology, 50(3), 1260–1268. doi:10.1021/acs.est.5b04983

4. Gu, J., Wensing, M., Uhde, E., Salthammer, T. (2019). Characterization of particulate and gaseous pollutants emitted during operation of a desktop 3D printer. Environment International, 123, 476–485. doi:10.1016/j.envint.2018.12.014

5. Zontek, T. L., Ogle, B. R., Jankovic, J. T., Hollenbeck, S. M. (2017). An exposure assessment of desktop 3D printing. Journal of Chemical Health and Safety, 24(2), 15–25. doi:10.1016/j.jchas.2016.05.008

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