| Process Type | Description | Common Technologies | Materials Used | Primary Hazards |
|---|---|---|---|---|
| Material Extrusion | A continuous filament of solid thermoplastic is fed through a heated nozzle, melted, and deposited onto a build platform along a defined path. The platform lowers as each layer cools and solidifies. | Fused Deposition Modeling (FDM); Bioprinting | Thermoplastics; PLA, ABS, PETG, Nylon; biological materials | Inhalation of volatile organic compounds (VOCs), particulates, and additives; thermal burns |
| Vat Polymerization | Liquid photopolymer resin is selectively cured using ultraviolet (UV) light. The build platform moves incrementally as each resin layer is hardened. | Stereolithography (SLA); Digital Light Processing (DLP); Masked Stereolithography (MSLA) | Photopolymer resins | Inhalation of VOCs; skin contact with resins and solvents; UV radiation exposure |
| Powder Bed Fusion | Thin layers of powder are evenly distributed across the build platform and selectively fused using a laser or electron beam. This process repeats until the part is fully formed. | Selective Laser Sintering (SLS); Direct Metal Laser Sintering (DMLS); Selective Laser Melting (SLM); Electron Beam Melting (EBM) | Nylon; stainless steel; titanium; aluminum; cobalt chrome; copper | Inhalation or skin exposure to powders and metal fumes; explosion risk; laser or radiation exposure |
| Material Jetting | Droplets of build material are deposited onto the build platform in a manner similar to inkjet printing. Each layer is solidified through cooling or UV curing. | Material Jetting; Drop-on-Demand | Polypropylene (PP); HDPE; PS; PMMA; PC; ABS; HIPS; EDP | Inhalation of VOCs; dermal exposure to resins and solvents; UV radiation exposure |
| Binder Jetting | A thin layer of powder is spread over the build platform, and a liquid binding agent is selectively applied to bond the particles. The process is repeated layer by layer. | Sand Binder Jetting; Metal Binder Jetting | Metals (stainless steel); polymers (ABS, PA, PC); ceramics (glass) | Inhalation or skin exposure to powders; explosion risk; inhalation of VOCs; dermal exposure to binders |
| Sheet Lamination | Sheets or ribbons of material are stacked and bonded using adhesives or ultrasonic welding. Each layer is cut to shape using a laser or blade before the next layer is applied. | Laminated Object Manufacturing (LOM); Ultrasonic Additive Manufacturing (UAM) | Paper; plastics; metals | Inhalation of fumes and VOCs; electrical shock; laser or radiation exposure; adhesive exposure. Laceration from contact with a cutting blade. |
| Directed Energy Deposition | Metal powder or wire feedstock is delivered through a nozzle and melted by a focused energy source as it is deposited onto the build surface. | Directed Energy Deposition (DED) | Cobalt chrome; titanium alloys; stainless steel; aluminum alloys; nickel; copper; superalloys; composites; functionally graded materials | Inhalation or skin exposure to powders and fumes; explosion risk; laser or radiation exposure |
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