3D Printing with Metal Powders: Health and Safety Questions to Ask

Review the questions on the left and explore different control options and other information to reduce your exposure on the right.

Centers for Disease Control

and Prevention

National Institute for Occupational 

Safety and Health

What potential hazards are associated

with metal powder 3D printing? What

metals are in the powder? Are there

known health effects from the metals

(see safety data sheets) or can they be

reactive with the air? What is the work

environment like (for example, an

open or isolated area)?

Could the work activities cause

exposure? How are you handling the

metal powders? What is the likelihood

of exposure? Can you change the way

you do the activity to reduce the

likelihood of exposure (high potential to

low)? Be aware of the other printing

activities occurring nearby. 

Based on the work activity or step in 

the printing process, what engineering 

controls will reduce the likelihood of 

exposure? What are the key design and

operational requirements for the

control? Consider fire and explosion

hazard of metal powder when

selecting controls.

If the measures above do not

effectively control the hazard, what

PPE can be used? Have you

considered PPE for other safety

hazards (such as static, fire,

explosion, and laser)?

Learn more about safely working with metal powders for 3D Printing DHHS (NIOSH) Publication No. 2020-114, https://doi.org/10.26616/NIOSHPUB2020114

Pre-printing

• Containment or local exhaust ventilation

close to powder handling activities (should

be HEPA-filtered and fire/explosion

appropriate)

Printing

• Printing with metal powders is typically

performed in an enclosed chamber,

and the potential for exposure to

emissions is low

Post-printing

• Controls listed for pre-printing

• Ventilated glove box or containment

system (for example, during cleaning and

finishing activities)

• Ventilated sieving or powder dumping stations

Maintenance and cleaning

• Local exhaust ventilation when handling

powders outside of containment

• HEPA-filtered and fire/explosionappropriate waste vacuum

• Grounding and bonding of equipment for

static, fire and electrical safety

• Sticky mats on floors at printing or powder

handling area exits/entrances

Potential hazards may include: 

• Breathing and skin contact with metals

• Static, fire and explosion

• High powered lasers

• Incorporate metal powder 3D printing

into workplace safety programs

• Develop standard operating

procedures and train workers

• Do not consume food or drinks in

work areas

• Restrict access to essential personnel

Printing considerations:

• Printer locations

• Grounding and bonding straps used when removing filters

• Written procedures covering receiving and disposal of metal powders, operation and

maintenance activities

• Properly handle filters during replacement, removal, and disposal, and check and replace

seals as needed

• Use signs to alert workers of hazards and appropriate actions to protect themselves

• Consider the reactivity of your base material when selecting cleaning materials, equipment,

and methods

Work environment best practices: 

• Print in a negatively pressured area with

a dedicated ventilation system, in an area

away from other work

• Appropriate fire suppression system

• Clean work areas frequently including

between prints and at least daily

• Use wet cleaning methods (do not dry

sweep or used compressed air)

• Handle and dispose of all waste materials

(including cleaning materials/gloves) in

compliance with all applicable federal,

state, and local regulations

Pre-printing 

Higher potential for exposures: 

• Loading powders manually into machine

• Sieving powder outside of machine

Lower potential for exposures:

• Enclosed powder loading

• Enclosed powder sieving

• Receiving and storing powder containers

Printing

Higher potential for exposures: 

• Other work activities nearby

Lower potential for exposures:

• Monitoring printing progress

(printing with metal powders is

typically performed in an enclosed

chamber, and the potential for

exposure to emissions is low)

Post-printing

Higher potential for exposures: 

• Removing powder or printed object from printer

• Moving powder/printed object around

work area

Lower potential for exposures:

• Post-process cleaning/finishing object inside

containment system

• Enclosed powder sieving and powder removal

Maintenance and cleaning

Higher potential for exposures: 

• Performing preventative maintenance

on printer

• Removing/installing high efficiency

particulate air (HEPA) filters

Lower potential for exposures:

• Cleaning printer equipment and tools

• Housekeeping

NANOTECHNOLOGY

RESEARCH 

CENTER

National Institute for Occupational Safety and Health

Wear PPE that is appropriate for the activities around you (for example, powder change out on the machine next to your work station may require you to wear the same level of PPE). While potential

exposures are typically lowest during the printing stage, work surfaces might still be contaminated with metal powders. If printing is interrupted, use the level of PPE needed when the machine is open. 

Follow proper PPE replacement practices. Do not wear PPE outside of work areas. Options for PPE include:

• Nitrile or chemical resistant gloves

• Lab coat or coveralls

Characterization of

Potential Hazards 

Personal Protective

Equipment (PPE) 

Engineering Controls

Work Activities 

1

2

3

Have you considered your

workplace practices and policies?

Have you set up a plan for waste

management? Have you considered

what to do in case of a spill?

4 Administrative Controls

5

• Safety glasses, goggles, or face shields

• Respiratory protection when indicated and engineering controls cannot control

exposures, and in accordance with federal regulations (29 CFR 1910.134)

• NIOSH guidance on respirators can be found at

www.cdc.gov/niosh/topics/respirators/

Applies to All Printing Stages

Applies to All Printing Stages

March 2020