WORKING WITH 3D PRINTER STANDARD OPERATING …ehs.ucr.edu/laboratory/UCR 3D PRINT Lab...

3D PRINT Lab SOP of 11 Version - 8/28/2017

WORKING WITH 3D PRINTER STANDARD OPERATING PROCEDURE

Type of SOP: Process Hazardous Chemical Hazard Class

1. HAZARD OVERVIEW

3D printing is an additive manufacturing technology used in rapid prototyping

and small-scale manufacturing of physical objects from a three-dimensional

digital model.

The hazards associated with 3D printing are related to the processes and

technologies applied. These may range from: hazards associated with

electrical/shock, electromechanical force, burns from molten materials,

ultraviolet light (UV)/ laser beams, and to health hazards associated with

inhalation of ultrafine and/or toxic smoke, fumes, dusts and chemical hazards.

In addition, some 3D Printing processes require post-printing caustic etchant

use, or other hazardous chemical processes. When installing 3D printers, all

hazards associated with the entire printing-process from installation to project-

set-up to production to post-printing processes must be considered for each

type of technology/application, as well as the site-specific work environment

where installed

The more common 3D print technologies on campus are Material Extrusion

and Vat Photo-polymerization.

Only authorized users are allowed to handle, move,

connect or touch 3D printers

2. HAZARD IDENTIFICATION

Material Extrusion-using either Fused Deposition Modeling®️ (FDM)/

Fused Filament Fabrication (FFF) use filaments (Thermoplastics) which

can be a(an) :

o Inhalation hazards, exposure to high concentrations of nanoparticles and Volatile Organic Compounds from thermal decomposition

o Fire hazard from contact with hot surfaces and post processing chemicals /due to electrical component failure

o skin and eye irritants/sensitizers from airborne contaminants and post processing chemicals

o Sharp tools may also be part of accessory kit

Vat Photo-polymerization-using either Stereolithograph Apparatus

(SLA)/ Digital Light Processing (DLP) use UV light and hazardous

monomers which can generate:


o Radiation hazard from UV light, especially damaging to skin and

vision

o Inhalation hazards exposure to high concentrations of nanoparticles

o Fire hazard from contact with hot surfaces and post processing chemicals /due to electrical component failure

o Its inherent support material and post-processing may use

hazardous propriety chemicals

Other 3D Printing Hazards

o Hot surfaces – print head block, heated beds and UV lamp

o High voltage/Electric risk – UV lamp connector, electric outlet and

ground wire

o Moving parts – printing assembly potential

entrapment/entanglement

3. ENGINEERING CONTROLS

Ventilation: Use 3D printers ONLY in well-ventilated areas. Task ventilation may be

useful for some styles and application of 3D printers; conduct work inside a fume hood

or low flow enclosures to prevent exposure if working in conjunction with volatile

compounds, thermoplastics that release toxic components (consult SDS) or

photopolymer which may have hazardous monomers such as acrylates. Any failure of

the external ventilation or any fumes in the 3D printer room/area should be immediately

reported to PI/Lab manager/EHS.

The hood flow meter should be checked to be operating correctly prior to using the hood

Fire/Hot surface: 3D printer needs to be regularly inspected and maintained.

Furthermore, printer should not be left unattended during operation for an extended

period of time. In order to prevent burns from hot surfaces, 3D printers should be

operated within an enclosure that prevents the user to come into contact with the

various parts which pose a risk of burn, such as the nozzle and heated bed.

As well, adequate signage should be present to warn the user not to tamper with the

enclosure or attempt to touch the printer as it operates.

Chemical Risk: Chemicals with hazardous properties such as flammables can be used

as part of the bed preparation or rinse. Always prepare the bed or post product in a well-

ventilated area designed to safely handle and contain chemicals and their associated

hazards.

Chemicals can also be used in post-printing processes, such as in material surface

finishing or for support material removal. Some support materials used in 3D printing

are removed by dissolving them in an alkaline bath or propriety chemicals. To avoid

chemical exposure while using this corrosive base bath, please see personal protective

equipment (PPE) protocol. Furthermore, an emergency eyewash is required in the


immediate vicinity of the work (i.e within 10 secs of unobstructed access). A spill kit

capable of neutralizing the caustic components of the alkaline bath must also be

available.

Moving Parts: 3D printers with enclosures should be equipped with an interlock system

which pauses any printing when the enclosure access is opened. If no interlock system

is present, users must always disengage the printer by turning off the printer main

power before manually moving the printer carriage along its axis.

Furthermore, users should confine long hair, loose clothing, or head scarves before

using any 3D printing devices.

High Voltage/Electrical Risk: Users should not remove instrument covers in order to

do repairs or modifications; the instrument’s manufacturer should be contacted instead.

Due to potential high voltage, only competent person(s) are allowed to remove

equipment covers. Users must always switch off a 3D printer and unplug it completely

from the main power supply if equipment covers are to be removed. The majority of

desktop 3D printers do not have any added electrical safety features or user-serviceable

parts beyond an internal fuse. Always consult manufacturer information before

attempting to service and 3D Printer yourself.

For 3D printers with UV lamps and lasers, ensure that printers are properly shielded to

prevent eye exposure. Don’t look at the lamp

Refer to Appendix 1 for overview of risk assessment form for controlling and managing

current and new hazards

4. PERSONAL PROTECTIVE EQUIPMENT (PPE)

For chemical exposure associated with post production processes:

a. Eye Protection

When using chemical that is a skin hazard or is a caustic liquid, use ANSI

compliant safety glasses and use a face shield if splashing onto the face is a

possibility. Also, use eye protection where airborne projectiles may be present

b. Skin and Body Protection

Wear long pants or equivalent, and closed-toe shoes. Laboratory coats must

be appropriately sized for the individual and be buttoned to their full length.

Laboratory coat sleeves must be of a sufficient length to prevent skin

exposure while wearing gloves.

Flame-resistant lab coat will be required, if working with large quantities of

flammable chemicals.


c. Hand Protection

At a minimum, wear neoprene or nitrile chemical-resistant glove. Consult with

your preferred glove manufacturer to ensure that the gloves planned to be

used are compatible with the chemical and usage.

http://www.ansellpro.com/download/Ansell_8thEditionChemicalResistanceGuide.pdf or http://www.showabestglove.com/site/default.aspx

A Laboratory Hazard Assessment must be conducted if additional PPE is required or if

procedures/processes present additional risk. It is the responsibility of the PI to ensure

that any additional PPE requirements are identified and communicated to research staff.

Contact EH&S (951-827-5288) for consultation.

5. SPECIAL HANDLING PROCEDURES AND STORAGE REQUIREMENTS

Changing cartridges: Inspect cartridge for damage and do not use if damaged. Undue

exposure to uncured 3D printer material is a potential hazard.

When handling damaged cartridges SEE PPE PROTOCOL. In case of leak, follow

spillage procedure and waste handling below. Undamaged cartridges do not pose a spill

risk – no protective equipment required.

If any novel use with additional potential hazards are being considered. Consult

manufacturer instructions, guideline & EHS at 951-827-5528

6. SPILL AND INCIDENT PROCEDURES

Chemical Spill - Dial 911 and EH&S 951-827-5528

Assess the extent of danger. Help contaminated or injured persons. Evacuate the spill

area. Avoid breathing vapors. If possible, confine the spill to a small area using a spill

kit or absorbent material. Keep others from entering contaminated area (e.g., use

caution tape, barriers, etc.).

• Small (<1L) – If you have training and are confident it is manageable, use

appropriate personal protective equipment and clean-up materials for chemical

spilled. Double bag spill waste in clear plastic bags, label, and arrange for

chemical waste pick-up.

• Large (>1L) – Dial 911 and EH&S at 951-827-5528 for assistance. Notify

others in area of spill. Turn off ignition sources in area. Evacuate area and post

doors to spill area. Remain on the scene, but at a safe distance, to receive and

direct safety personnel when they arrive.

Exposure to cleaning solvents –

Chemical Spill on Body or Clothes – Caustic and corrosive materials quickly destroy

skin or tissue if splashed on the body or in the eyes. Remove clothing and rinse body

http://www.ansellpro.com/download/Ansell_8thEditionChemicalResistanceGuide.pdf

http://www.ansellpro.com/download/Ansell_8thEditionChemicalResistanceGuide.pdf

http://www.showabestglove.com/site/default.aspx


thoroughly in emergency shower for at least 15 minutes. Seek medical attention. Notify

supervisor and EH&S at 951-827-5528 immediately.

Chemical Splash Into Eyes – Immediately rinse eyeball and inner surface of eyelid with

water from the emergency eyewash station for 15 minutes by forcibly holding the eye

open. Seek medical attention. Notify supervisor and EH&S at 951-827-5528

immediately.

Medical Emergency - Dial 911 and EH&S 951-827-5528

Refer to “Injuries and Medical Treatment” Flipchart posted in the laboratory.

7. DECONTAMINATION

Wear proper PPE. Dispose of all used contaminated disposables as hazardous waste

following the Waste Disposal Section.

8. WASTE DISPOSAL

All waste must be disposed through the EH&S Hazardous WASTe Program. Staff

dealing with hazardous waste disposal should have completed UCR Hazardous Waste

Management training - http://ehs.ucr.edu/training/online/hwm/indexlms.html

General hazardous waste disposal guidelines:

• Affix an on-online hazardous waste tag using the WASTe Program

(https://ehs.ucop.edu/waste/#/ ) on all waste containers as soon as the first drop

of waste is added to the container.

• Store hazardous waste in closed containers, in secondary containment, and in

a designated location. Do not let product enter drains. Discharge into the

environment must be avoided.

• Double-bag dry waste using transparent bags.

• Waste must be under the control of the person generating and disposing of it.

• Dispose of routinely generated chemical waste within 90 days.

• Request a waste pick-up on-line: http://ehs.ucr.edu/services/waste.html

9. PRIOR APPROVAL/REVIEW REQUIRED

All work with 3D printers must be pre-approved by the Principal Investigator prior to use

and all training must be well documented. Person(s) working with hazardous chemicals

used in 3D printing are required to take one of two safety training classes, depending on

their working environment:

Hazard Communication (Non-Lab setting) or

Laboratory Safety Fundamentals (2013) & Hazardous Waste Management (Lab setting)

https://ehs.ucop.edu/waste/#/


In addition, the following shall be completed:

• Documented specific training and specific training on the techniques and

processes to be used.

• Read and understand the relevant Safety Data Sheet.

• Demonstrate competence to perform work.

A review of this SOP and re-approval is required when there are any changes to

procedures, personnel, equipment, or when an incident or near miss occurs.

10. SAFETY DATA SHEETS

Online SDS can be found at http://www.ehs.ucr.edu/services/msds.html

11. DETAILED PROTOCOL

Please Follow Instruction Manual

In addition, when working in the lab, a laboratory worker must:

Always follow manufacturer guidelines, be cognizant of all of the SDS and safety

information presented in this document

Consult EH&S for a hazard assessment when considering modifications/ novel

uses

Notify coworkers before beginning non-routine and hazardous work. To work

alone; facility must have work alone protocol

To prevent respiratory irritation, work in a well ventilated room

Once a printing job is started, do not open cover, or defeat/override interlock

switch

If interlock safety switch fails, do not use the printer

As determined by the hazard assessment, in addition to all pertinent laboratory

personal protective equipment (PPE), chemical protective gloves and suitable

dust mask may be required when accessing the printer stage area after printing

Uncured material may be hazardous; wear suitable/ recommended glove

protection and if material can splash, wear safety goggles

In the event of leak/ spill of printing material cartridges, use solvent-absorbent

pads for model/ support material spills. Dispose clean-up materials as chemical

waste. Contact UCR EH&S 951-827/5288 when responding to any major spills

Keep model and support materials away from areas where cosmetics are

applied, or food and drink are stored, prepared or consumed

Follow all related SOPs in the laboratory SOP bank (PPE, waste disposal, etc. as

appropriately modified by any specific information in the SDS information

presented in this document

discuss ALL issues or concerns regarding this 3D Printer with the PI prior to its

use

http://www.ehs.ucr.edu/services/msds.html


If there is an unusual or unexpected occurrence when using this material(s), the

occurrence must be documented and discussed with the Principal Investigator or Lab

Supervisor and others who might be using the 3D Printer. Unusual or unexpected

occurrences might include a fire, explosion, sudden rise or drop in temperature.

____________________________________________________________________

Principal Investigator or Lab Supervisor SOP Approval

Print name: _________________________Signature___________________________

Approval Date:

[Chemical Name] SOP of 11 PI Name Version - 8/28/2017

Acknowledgement Standard Operating Procedure

Title: 3D PRINT LAB By my signature I acknowledge the contents, requirements, and responsibilities outlined in this Standard Operating Procedure (SOP):

Name Identification* Signature Date

*Identification: Enter your Student ID, Employee ID, UCR NetID, UCR Email


A P P E N D I X 1


3D PRINTER RISK ASSESSMENT FORM

UCR EHS CHECKLIST

INSTRUCTIONS FOR USE: This checklist is designed to enable the user of 3D printers, in consultation with their PI/Lab manager/Supervisor, identify hazards associated with and prior to, their intended use of a 3D printer. When planning the use of a 3D printer, the recommended risk controls listed below should be considered and incorporated where relevant to reduce the level of risk. Other controls not already covered that are unique to the functions of 3D printers should also be considered and recorded. Refer to Appendix 1 Risk Assessment Matrix for explanation on risk ratings. Retain copies of completed forms on a shared drive and make accessible for the purpose of auditing.

Name of User: Click here to enter text.

Facility : Click here to enter text.

3D Printer Model: Click here to enter text.

Date checklist completed: Click here to enter a date.

Name of Supervisor consulted: Click here to enter text.

Date checklist reviewed: Click here to enter a date.

Item Hazard description How exposed to hazard

Risk Rating –

before controls (High/Medium/

Low)

Recommended risk control measures – (when implemented these controls are designed to reduce risk to as low as reasonably achievable)

Select controls to be incorporated

By whom

1 Fumes/Ultrafine

Particles

Potential Health effects on respiratory system from long term exposure

M

In built HEPA filters and enclosed system ☐

Adequate ventilation or Local air exhaust system ☐

Safety Data Sheet (SDS) ☐

Add other controls unique to use of your 3D Printer. ☐

2 Chemicals

Contact with caustic bath chemicals Contact with post processing chemicals and solvents

L

Enclosed system ☐

Training, SOP & SDS ☐

PPE: Gloves & Chemical Spill Clean-up Kit ☐


3 Fire

Contact with post processing chemicals

Fire in unit due to electrical component failure

L

Repairs and modifications by competent person only ☐

Regular Maintenance & Electrical Inspection Test & Tag ☐


4 Heat

Contact with hot extrusion head or finished model could cause burns

L

Enclosed system ☐

Training & SOP ☐


5 Electric Shock

Contact of persons with live parts.

Contact of persons with parts which have become live under faulty conditions.

L

Restricted Access to Students ☐

Repairs and modifications by competent person only ☐

Regular Maintenance & Electrical Inspection Test & Tag ☐

Training & Standard Operating Procedure (SOP) ☐


6 Entrapment/

Entanglement Contact with Moving Parts L

Enclosed system around moving parts, guarding ☐

Training prior to operation of printer ☐


NOTE: Implementation of risk controls should be reviewed regularly to ensure they remain effective in minimizing injury/illness.


Risk Assessment Matrix – The risk matrix below is used to determine the level of risk for each hazard.

RISK SEVERITY/CONSEQUENCE

LIKELIHOOD

CRITICAL

(may cause severe injury or fatality - more than two weeks lost

time)

MAJOR

(injury resulting in at least one day lost time)

MINOR

(medical treatment injury - back to work)

NEGLIGIBLE

(first aid treatment - no lost time)

VERY LIKELY (5)

(exposure happens frequently)

High

High

Medium

Medium

LIKELY (3-4)

(exposure but not frequently)

High

Medium

Medium

Low

UNLIKELY (1-2)

(exposure could happen but only rarely)

Medium

Medium

Low

Very low

VERY UNLIKELY (1)

(Exposure can happen but probably never will)

Medium

Low

Very low

Very low

Risk Priority Table

Risk priority Definitions of priority Time frame

High (5) Situation critical, stop work immediately or consider cessation of work process.

Hazard should be controlled as soon as practical. Consider short term and/or long-term actions. ASAP

Medium (3-4) Must be investigated to determine effective risk mitigation benefits/control measures. Consider short term and/or long-term actions.

1 – 4 weeks

Low (1-2) Still important but hazard can be controlled through scheduled maintenance or similar type programming.

1 - 3 Months

Very low (1) Review and/or manage by routine processes. Do not require any further assessment or analysis. N/A

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