ADDITIVE MANUFACTURING/3D PRINTING
FEATURE
TEMPERATURE CONTROL – HELPING ADDRESS THE HOTTEST TOPIC IN ADDITIVE MANUFACTURING
Nigel Bedford, technical development manager at Donaldson
BOFA, explains why temperature control and emissions extraction are essential for success and safety during additive manufacturing
I
nnovations in additive manufacturing (AM) and materials science are enabling an ‘anything and everything on demand’
revolution in 3D printing. Traditional manufacturing processes are
increasingly being replaced by AM systems and, even where a traditional approach provides a more cost-effective option, 3D printers are often an enabler for those solutions – by printing tooling, for example. In step with this widening horizon, 3D
print capability is itself constantly evolving to optimise the value of progress in another area of innovation – materials technology. A good example is PEEK
(Polyetheretherketone), a very high performance and durable material used in the aerospace, automotive, and oil and gas industries, which is now crossing into new applications,
including PEEK printed medical devices.
SAFETY It’s an exciting time to be involved in AM, but it’s also worth remembering that there are two fundamental pre-requisites for success and safety, including temperature control and emissions extraction, with Donaldson BOFA systems playing a critical role in both. Chamber temperature control is essential
because, by definition, 3D printers operate in a narrow temperature envelope from the bed up to ensure that feed material reaches the critical point where it can be layered and bonded. Likewise, the cooling process must be carefully controlled to avoid the risk of embrittlement. Getting the relationship right between
maintaining a precise operating temperature and achieving effective filtration is critical in optimising the value of new-generation functional materials. These are purposely designed to exhibit specific properties, such as scratch resistance and tensile strength, but increasingly need higher temperatures to deliver their functional benefits. Of course, the principal
role for Donaldson BOFA systems is to filter the nanoparticles, particles and VOCs that are emitted as a result of 3D printing, the concentration of which increase as
temperature rises. Indeed, research into 3D printing emissions linked to polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), undertaken by the UK’s Health & Safety Executive and separately by the National Institute for Occupational Safety and Health in the US, found that heated filaments emitted
Donaldson-BOFA 3D PrintPRO HT
large numbers of very small particles and VOCs. PLA and ABS are the two most common plastic materials used in extrusion-based 3D printing processes.
PLA is manufactured from lactic acid and is known to release lactide as a gas when processed, while ABS emits styrene during printing. The studies highlighted that these emissions could be controlled through measures such as effective filtration and, where material composition permits, lower printing temperatures.
PROTECTING OPERATORS Not all 3D printing emissions are in concentrations harmful to human health but, even so, where they are present, fume extraction is recommended to maintain both operator comfort and a sense of reassurance within the work environment. Achieving both temperature control and
filtration performance is essential. For Donaldson BOFA this means ensuring that the process of recirculating chamber air to extract emissions is achieved without detriment to the required operating conditions. For example, 3D PrintPRO HT technology
incorporates airflow innovations that actively help maintain optimal temperature conditions during 3D print operations. At the end of the process, the extraction system runs a purge cycle that helps cool the chamber progressively and methodically while passing the air through a carbon filter to help remove any VOCs that continue to be released. Without this offline bypass, the carbon filter layer would be ineffective due to the elevated temperatures involved. These advances result from a close working
relationship with 3D print equipment manufacturers, materials technology companies and end users. This partnership approach not only ensures that extraction systems help deliver the effective filtration of particulate and gases to optimise 3D print quality, it also creates an innovation mindset that anticipates the extraction needs of a constantly evolving ‘anything and everything on demand’ manufacturing industry.
Donaldson BOFA
donaldsonbofa.com
NOVEMBER 2024 DESIGN SOLUTIONS 43
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