A recent study by the Finnish Institute of Occupational Health shows that the greatest health risk in additive manufacturing with metal powders is not during the printing process itself, but in the subsequent post-processing. High concentrations of fine and ultrafine particles that can be inhaled are released, particularly during work steps such as grinding, milling or cutting additively manufactured components.
While the actual 3D printing process takes place in closed systems and only generates low levels of particles, air and skin samples from the study showed that significantly higher levels can occur in the post-processing phase. This applies in particular to metallic aerosols, which can penetrate deep into the respiratory tract due to their small particle size.
“Workplaces should pay more attention to exposure control during post-processing. In our measurements, high concentrations of fine and ultrafine particles were occasionally detected during these tasks,” says Maija Leppänen, Senior Research Scientist at the Finnish Institute of Occupational Health.
The study also examined the effectiveness of protective measures. Despite measurable metal exposure, biomonitoring data showed no evidence of inflammatory respiratory reactions, which can be attributed to the consistent use of personal protective equipment (PPE).
“Although metal 3D printing involves exposure risks, proper protective measures and safe work practices can limit internal exposure to minimal levels,” Leppänen explains.
As part of the project, a practice-oriented model for hazard assessment and risk minimization in metal-based 3D printing was also developed. It contains recommendations on process design, the selection of suitable PPE and workplace organization and is available in English. The aim is to provide companies with a sound basis for improving occupational health and safety in additive manufacturing environments.
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