By Ignacio Sandoval, Senior Forensic Engineer, EFI Global
3D printing, also known as additive manufacturing, is reshaping how we build the world around us. Industries across the globe are embracing it to create everything from life-saving medical devices, construction molds and consumer goods to engine parts for cars and spaceships.
With great innovation comes new challenges, and while we can marvel at the advancements and possibilities of 3D printing, we also need to understand the unique risks it poses. Let’s delve into the world of 3D printing and uncover its hazards.
The power of 3D printers
3D printers are becoming so widespread that some hobbyists have them in their homes. The desktop versions cost between $200 and $10,000 and use mostly plastics to create small trinkets and prototypes for personal use. While impressive, these compact machines pale in comparison to what the industrial or commercial versions can do. Commercial printers are much larger in size, use a wider range of materials and can take on bigger projects, like creating the critical components in airplanes and automobiles, and producing full-scale building components. These machines can cost upwards of six figures and require significant expertise to operate safely.
Understanding the risks
There are inherent risks associated with 3D printers based on how they’re made and how they function. Their high operating temperatures, explosive dust and electrical demands put them at risk for fire and explosions, among other risks.
High temperatures and ignition hazards
Some 3D printers operate at temperatures over 750 degrees Fahrenheit, and at that extreme heat, even a minor malfunction can lead to catastrophe. Heating elements, lasers and motors — all essential for the printer’s function — can become ignition sources if something goes awry.
Electrical overloads
Commercial printers need substantial electrical power. If the right infrastructure isn’t in place, circuits can overload and spark fires.
Explosive materials
Some 3D printing methods use fine powders, which can be as explosive as gasoline vapors. Without proper ventilation and handling, these powders pose a severe risk.
Mechanical failures
3D printers are complex, and when there’s a mechanical failure, it can halt operations and be costly to repair. Motors can burn out from jams, cooling systems can fail and overheat, and sensitive electronic components can be destroyed by power surges.
External factors
Water damage from floods, damage from fallen debris during natural disasters and contamination from dust or smoke can all compromise these sophisticated machines.
Learning from the past
In 2016, a young enthusiast sought to improve his 3D printer’s performance by using hairspray to help objects stick better during printing. The result was catastrophic. Fumes from the flammable spray ignited, leading to an explosion that claimed his life.
In another incident, a desktop printer was left running an 11-hour job. An electrical short sparked a fire, engulfing the printer and causing significant damage – though no one was injured.
Incidents happen using commercial 3D printers too. NASA printed a combustion chamber that could be used in one of its rocket engines, and it split in half during test firing. The printer that was used to make the chamber paused partway through the print, and that pause created a weak spot – or witness line – on the chamber. This spot couldn’t withstand the high pressures and temperatures, and the chamber split and burst into flames.
Preparing and responding
For desktop and commercial 3D printers alike, it’s essential that operators follow the printer manufacturer’s installation and maintenance guidelines and receive proper training. Equally important is making sure electrical systems can handle the demands of 3D printers and that these printers are included as part of disaster preparedness plans.
When an incident does occur, it can be daunting. Specialized professionals can help navigate these challenges effectively, no matter how complex. Fire investigators and forensic engineers can determine the origin and cause. Industrial hygienists can assess risk from any toxic exposures (especially important when powders or fumes are involved). Structural engineers evaluate damage to facilities and guide safe rebuilding efforts. Equipment consultants can assess damaged printers and pinpoint where they failed.
Assembling the right team ensures accurate assessments, proper scoping of damages and the pursuit of any potential recoveries.
Embracing the future
3D printing is revolutionizing the way things are made – both in factories around the world and by enthusiasts at home. As this technology becomes more widespread and its applications continue to expand across industries, we need to be aware of the fire and explosion risks these printers pose. While we embrace the future of manufacturing, let’s also embrace staying prepared by following safety protocols and pulling in the right experts to respond to any incident.
Staying informed and connected
To delve deeper into this topic, read our full commentary paper or reach out to an EFI Global expert.