UL SUBJECT 3400-2017 UL Outline for Investigation Additive Manufacturing Facility Safety Management (Issue 1).pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULOCTOBER 31, 20171UL 3400Outline of Investigation for Additive Manufacturing Facility SafetyManagementIssue Number: 1October 31, 2017Summary of TopicsThis first issue of the Outline of Investigati

2、on for Additive ManufacturingFacility Safety Management, UL 3400, applies to additive manufacturingfacilities using powder as feedstock material for printing of parts.ULs Outlines of Investigation are copyrighted by UL LLC. Neither a printed norelectronic copy of an Outline of Investigation should b

3、e altered in any way. All ofULs Outlines of Investigation and all copyrights, ownerships, and rights regardingthose Outlines of Investigation shall remain the sole and exclusive property of ULLLC.COPYRIGHT 2017 UL LLCUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITH

4、OUT PERMISSION FROM ULOCTOBER 31, 2017UL 34002No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTS1 Scope .42 Introduction 43 Hazard Classification 63.1 General .63.2 Material hazards 63.3 Equipment hazards .73.4 Facili

5、ty hazards 94 Units of Measurement 105 Normative References 106 Glossary 137 Design Requirements for the Facility .138 Design Requirements for the Equipment 188.1 AM machine 188.2 Ancillary AM equipment 188.3 Safety equipment 199 Design Requirements for the Materials .219.1 Material storage .219.2 W

6、aste disposal 229.3 Waste from wet separator 2210 Process Safety Information (PSI) .2311 Standard Operating Procedure (SOP) .2612 Emergency Planning and Response (EPR) 2813 Process Hazard Analysis (PHA) 2913.1 General .2913.2 Quantifying risk 2913.3 Risk levels .31OCTOBER 31, 2017 UL 3400 3UL COPYRI

7、GHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL1 Scope1.1 This outline covers Additive Manufacturing (AM) facility safety management. It addresses the varioushazards associated with material, equipment and facility where parts are manufactured usingpo

8、wder-based additive manufacturing techniques. It covers the potential hazards and risk mitigationmeasures required for the safe functioning of the facility. These foreseeable hazards include, but are notlimited to, fire and explosion, toxic exposure and other workplace hazards. This outline of inves

9、tigationalso includes recommendations for the design, installation and maintenance of additive manufacturingfacilities (powder based).1.2 This outline covers the physical space belonging to the primary AM equipment, ancillary AMequipment and powder storage area unless otherwise specified. In order t

10、o fully address the potentialhazards, the outline adopts the approach as represented in Figure 1.1.This is generated text for figtxt.2 Introduction2.1 A broad classification of AM Systems based on the initial form of feedstock material (material withwhich the part is built) is as follows:a) Powder b

11、ased AM systems metals, polymers and ceramics:1) Selective Laser Melting, SLM (metals);2) Electron Beam Melting, EBM (metals);Figure 1.1Additive Manufacturing Facility Safety Management ApproachOCTOBER 31, 2017UL 34004UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WIT

12、HOUT PERMISSION FROM UL3) Directed energy deposition (metals):i) Laser Engineered Net Shaping, LENS; andii) Rapid Plasma Deposition, RPD.4) Selective Laser Sintering, SLS (polymers);5) Multi jet fusion technology (polymers); and6) Binder jetting (ceramics).b) Liquid based (vat polymerization) AM sys

13、tems Resins, Photopolymers:1) Stereo Lithography Apparatus, SLA (photopolymers);2) Direct Light Processing, DLP (photopolymers); and3) Continuous Liquid Interface Production, CLIP (photopolymers).c) Solid based AM systems Wires, Laminates, Pellets:1) Fused Deposition Modeling, FDM (polymers-wire);2)

14、 Electron Beam Wire Feed, EBAM (metals-wire);3) Laminated Object Manufacturing, LOM (laminates-paper and plastics); and4) Ultrasonic Consolidation, UC (metals).2.2 AM facilities that utilize Powder Bed Fusion (PBF) process to create parts make use of metal powders(in Selective Laser Melting, SLM) an

15、d polymer powders (in Selective Laser Sintering, SLS) as feedstockmaterial.2.3 A variety of metals and alloys including aluminum, cobalt, nickel, stainless steel and titanium are usedin SLM process. The building process generally takes place in an inert atmosphere using gases such asnitrogen, argon

16、etc. Nitrogen is typically used for stainless steel, nickel alloys and cobalt chrome. Argonis used when fabricating parts using aluminum and titanium powders. The additive manufacturing system,raw powder, filter system, and ancillary AM equipment (e.g. wet separator vacuum) all pose safety andenviro

17、nmental hazards which shall be covered by this outline.2.4 SLS process employs various polymer powders such as Polyamide 12 (Nylon12), Polyamide 11,Polyamide 12 with Aluminum/Carbon fiber/Glass bead, Polyether Ether Ketone (PEEK), ThermoplasticPoly Urethane (TPU), Thermoplastic Elastomer (TPE), Poly

18、carbonate, PEBA, etc. to produce plasticparts.OCTOBER 31, 2017 UL 3400 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL2.5 Binder Jet Process uses a number of ceramic powders (in addition to metal powders) for printing ofparts. Commonly used

19、ceramic materials include but are not limited to: aluminum oxide, calcium sulfate,silica, ceramic sand, gypsum and glass.3 Hazard Classification3.1 General3.1.1 The list of hazards included in this section are currently identified and addressed by this outline. Thelist is not exhaustive and the risk

20、s shall depend upon the specific nature of each material and type of AMequipment used within an individual facility.3.2 Material hazards3.2.1 Deflagration and Detonation Hazards: The combustion hazard of a potential powder dust cloudunder the right conditions. It can be a deflagration (combustion zo

21、ne propagating at less than the speedof sound) or a detonation (the flame front travelling at greater than the speed of sound). Dust cloud ignitionmay be caused by many factors such as presence of explosible concentrations of dust and oxidizers,ignition sources such as sparks, arc discharges, hot su

22、rfaces, friction, etc.3.2.2 Exposure Hazards Single and Systemic (Metal powders): Accidental exposures (spills and falls)or long term industrial exposure that may cause dermatitis, skin ulcers, perforation of the nasal septum,as well as cancers of the lungs, nasal cavity and paranasal sinuses.3.2.3

23、Exposure Hazards Single and Systemic (Polymer powders): Polymer powders upon burningproduce many noxious and toxic fumes. These thermal decomposition products include carbon dioxide,carbon monoxide, and aldehydes.3.2.4 Flammability Hazards: Hazard of catching fire or release of highly flammable gase

24、s when powderscome in contact with water, oxidizers, alkalis or other incompatible materials.3.2.5 Health Hazards: Effects of overexposure to metal powders may include lung effects (irritation,fibrosis, asthma), cardiovascular effects (cardiomyopathy), liver and kidney congestion. Systemic effectsfr

25、om ingestion of nickel salts include capillary damage, kidney damage, myocardial weakness and centralnervous system depression.3.2.6 Ingestion Hazards: Ingestion may cause gastrointestinal irritation with nausea, vomiting anddiarrhea.3.2.7 Inhalation Hazards (Metal Powders): Repeated inhalation may

26、cause allergic respiratory reaction(asthma). Chronic inhalation of metal powders can result in mottling of the lungs, a condition referred toas siderosis.3.2.8 Reactivity Hazards (Metal powders): When they come in contact with incompatible materials, metalpowders can cause hazardous decomposition pr

27、oducts. For example, metals such as maraging steelsupon contact with mineral acids cause the release of hydrogen gas and may form explosive compoundswith air; or aluminum powders may react with water causing the formation of hydrogen.OCTOBER 31, 2017UL 34006UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR

28、 FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL3.2.9 Decomposition Hazards (Ceramic powders): When burning or at high temperatures, ceramicpowders release hazardous decomposition products such as oxides of sulphur and calcium, carbondioxide and carbon monoxide.3.2.10 Toxicity Hazards

29、: Exposure to metal dusts and oxides may cause metal fume fever. Many of themetals such as cobalt and nickel are considered possibly carcinogenic to humans.3.2.11 Chemical Hazards: A risk of damage to the respiratory tract and lungs exists when handling metalpowders and filter dusts. It may cause da

30、mage to the eyes if metal powder or dust gets into the eyes.Many metal powders and dusts are suspected of being carcinogenic to humans.3.2.12 Indoor Pollution Hazards (Ceramic powders): Quartz particles of size less than 1 micron stayairborne for extended periods of time, sometimes for several days.

31、 These particles are small enough topenetrate and clog the air pockets in lungs and cause silicosis resulting in shortness of breath, cough,bluish skin and fever.3.3 Equipment hazards3.3.1 Electrical Energy Hazards: Dangerous voltages of electrical circuits and stored electric chargesfrom electronic

32、 components pose life threatening hazards such as serious burns and electrocution.3.3.2 Electromagnetic Hazards: High frequency devices can interfere with some of the AM machines andresult in erratic machine behavior which poses a threat to operating personnel.3.3.3 Entrapment Hazards: Body or limbs

33、 such as hands and legs may get trapped inside a machineenclosure or between moving parts.3.3.4 Fire and Explosion Hazards: There are explosion hazards from reactive metal-air mixtures.Accidental swirling up of metal powder residues, process-related soot and filter residues in an atmospherecontainin

34、g oxygen may produce an explosive atmosphere.3.3.5 General Operational Hazards:a) Risk to life from non-functioning and/or malfunctioning safety equipment;b) Injuries from slipping on metal dusts; andc) Injuries from falling or tripping.3.3.6 Hazards caused by non-ergonomic equipment:a) Operators po

35、sition and location of controls;b) Difficulty of access for settings, adjustments, powder filling and removal, cleaning; andc) Unsafe zone for operation and maintenance of AM equipment.OCTOBER 31, 2017 UL 3400 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PE

36、RMISSION FROM UL3.3.7 Hazards from Hot Surfaces: Hot surfaces such as build plate, re-coater blade, electric motors andheater coils have the potential to cause serious burn injuries.3.3.8 Inert Gas Hazard:a) Oxygen depletion;b) Inert gas asphyxiation; andc) Suffocation from leakage of toxic gases.3.

37、3.9 Irradiation Hazards: There is a danger of injury from laser radiation and electron beams. Whendirectly looked upon by the naked eye, laser radiation can destroy the retina. Laser radiation (direct orscattered) is dangerous to the skin and can cause burns. It can also cause fires and explosions.3

38、.3.10 Mechanical Hazards:a) Moving parts of the machine;b) Sharp edges and corners;c) Heavy building platform and build plate;d) Broken optical components; ande) Pinch point injuries.3.3.11 Noise Hazards: There can be noise and vibrations from external sources.3.3.12 Pneumatic Equipment Related Haza

39、rds:a) Leaks;b) Bursting of hoses; andc) Whiplashing of unsecured compressed air hoses under pressure.3.3.13 Compressed Gas Systems: This refers to accidental releases such as compressed air outflows.3.3.14 Thermal Hazards: This refers to the risk of injury from hot surfaces such as build platform.O

40、CTOBER 31, 2017UL 34008UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL3.4 Facility hazards3.4.1 Air quality hazards:a) Inadequate oxygen content in breathing air; andb) Suspended particles and contaminants.3.4.2 Emergency evacuation related h

41、azards:a) Insufficient number of emergency exits;b) Improper location of emergency exits;c) Inaccessibility of egress points; andd) Lack of emergency evacuation readiness.3.4.3 Inadequate first aid measures for:a) Burns from powder and dust fires;b) Accidental exposure to eyes;c) Accidental exposure

42、 to body; andd) Poisoning from inhalation of inert gases and toxic fumes.3.4.4 Explosive atmospheres hazards:a) Presence of spontaneously inflammable fine metal powder dispersed in air; andb) Hazardous ancillary AM equipment.3.4.5 Fire hazards:a) Lack of proper firefighting systems;b) Incompatible p

43、ortable firefighting media;c) Incompatible fixed suppression system media;d) Insufficient fire rating of facility construction; ande) Lack of fire safety training for personnel.OCTOBER 31, 2017 UL 3400 9UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION

44、 FROM UL3.4.6 Non-optimal ambient conditions:a) Temperature; andb) Humidity levels.3.4.7 Static electricity hazards:a) Generation, accumulation and discharge of static charges;b) Dry non-humid ambient conditions;c) Insulated surfaces; andd) Lack of conductive paths.4 Units of Measurement4.1 Values s

45、tated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.4.2 Metric units shall be used throughout this outline unless otherwise mentioned. Imperial equivalentswill be used additionally wherever deemed necessary.5 Normative References5.1 AM facil

46、ities covered by this outline shall comply with the reference standards noted in this section asappropriate for the country where the facility is to be installed. When the facility is intended for use in morethan one country, it shall comply with the standards for all countries where it is intended

47、to be installed.5.2 Any undated reference to a code or standard appearing in the requirements of this outline shall beinterpreted as referring to the latest edition of that code or standard.5.3 Portions of these referenced standards as identified in this outline are essential for compliance. Thecode

48、s and standards that have been adopted by a jurisdiction control the requirements for AdditiveManufacturing equipment placement, facility design and safety requirements. Examples of these codesare listed below.ASTM StandardsASTM C33Standard Specification for Concrete AggregatesASTM F2413-11Standard

49、Specification for Performance Requirements for Protective (Safety) Toe Cap FootwearEN StandardsEN 143Respiratory Protective Devices Particle Filters Requirements, Testing, MarkingEN 166Personal Eye-Protection SpecificationsOCTOBER 31, 2017UL 340010UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULEN 374Protective Gloves Against Chemicals and Micro-Organisms Part 1: Terminology and PerformanceRequirementsEN 407Protective Gloves Against Thermal Risks (Heat and/or Fire)EN 61340-4-3Electrostatics Part 4-3: Sta