Analysis of gaseous emission and particle number size distributions in metal casting processes with binder jetting moulds

Abstract

The impact on indoor air quality during metal casting processes using the 3D printing (3DP) binder jetting technique to manufacture moulds is analyzed in this research. This study investigates the particle size distribution and gas concentration during the manufacturing stages of 3DP moulds, with focus on particle deposition in the human respiratory system. The goal is to understand the risks associated with particle and gas emissions in binder jetting 3D printing, and thus improve worker safety. The results indicate that particle emission rates are lowest during printing (0.01 1011particles min−1) but increase during post-processing and melting-pouring phases (3.07 1011 particles min−1). During melting and pouring, the emission of particles was mainly in the range 7.9–71 nm, with values 10 times higher than in the previous phases. The study calculates the deposition of inhaled particles in different parts of the respiratory tract and reveals a 2.39 times higher extrathoracic mass deposition during 3DP mould manufacturing stages compared to melting-pouring stages. Additionally, alveolar mass deposition is higher during melting-pouring stages due to an increase in ultrafine emission rates. The study emphasizes the importance of insulation equipment and workplace ventilation in indoor spaces, particularly during heating processes that generate ultrafine particles through nucleation, so that health risks can be mitigated.