Prototyping is an essential part of product development, allowing you to bring your ideas to life, test concepts, and make improvements before full-scale production. But while it’s exciting to see your designs take shape, it’s important to remember that prototyping comes with its own set of safety risks. Whether you’re working with 3D printers, CNC machines, laser cutters, or handling hazardous materials, following proper safety protocols is crucial to avoiding accidents and ensuring a safe work environment.
In this guide, we’ll break down the do’s and don’ts of safe prototyping, covering the potential hazards and best practices to ensure that your prototyping process runs smoothly – without any unnecessary risks.
Table of Contents
1. The Importance of Safety in Prototyping
2. Do’s and Don’ts of Safe Prototyping
3. Safe Prototyping Practices by Method
4. Responding to Accidents and Emergencies
Final Thoughts: Prototyping Without the Hazards
1. The Importance of Safety in Prototyping
Prototyping often involves working with powerful machinery, sharp tools, high temperatures, and potentially hazardous materials. Ignoring safety protocols can result in injuries, equipment damage, or even health risks from exposure to harmful substances. That’s why it’s essential to implement safety measures from the start and ensure that everyone involved in the prototyping process understands the risks and follows proper procedures.
Example: A maker creating a 3D-printed prototype may handle heated extruders or work with resins that can release harmful fumes. Without proper precautions, this could lead to burns or inhalation of toxic chemicals.
2. Do’s and Don’ts of Safe Prototyping
a) Do Wear Appropriate Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) is your first line of defence against many of the hazards involved in prototyping. Depending on the materials and equipment you’re using, you should wear appropriate PPE such as gloves, goggles, face shields, and respirators to protect yourself from chemical exposure, flying debris, or burns.
- Do: Always wear eye protection when using machinery like CNC mills or laser cutters, as debris or sparks can cause serious eye injuries.
- Do: Wear a respirator when working with materials like SLA resin or solvents, which can release harmful fumes.
Example: A worker using a laser cutter to engrave acrylic sheets should wear safety goggles rated for the specific laser type to prevent eye damage.
b) Don’t Ignore Ventilation Requirements
Many prototyping processes, particularly those involving 3D printing, laser cutting, or resin casting, release fumes or particulates that can be harmful if inhaled. Always ensure that your workspace is properly ventilated or use fume extraction systems to minimize exposure to toxic gases and particles.
- Do: Work in a well-ventilated area or use a fume extractor when 3D printing with materials like ABS or resin, which can emit harmful vapours.
- Don’t: Use enclosed spaces for processes like SLA printing or solvent-based finishing without adequate ventilation.
Example: A startup using FDM 3D printers for rapid prototyping in a small office should install ventilation systems to remove potentially harmful VOCs emitted by the filament during printing.
c) Do Follow Machine Safety Protocols
Prototyping often involves the use of machinery like CNC routers, laser cutters, or 3D printers. Following machine safety protocols is critical to avoiding injuries such as cuts, burns, or even electrical hazards. Always follow the manufacturer’s guidelines and ensure that you’re trained in the proper use of the equipment.
- Do: Keep hands and loose clothing away from moving parts, and ensure machines are properly secured and calibrated before use.
- Do: Perform regular maintenance checks on equipment like CNC machines to ensure they’re operating safely and efficiently.
- Don’t: Operate equipment without understanding its safety features, such as emergency stop buttons or safety guards.
Example: A company using CNC machines to mill prototypes must train operators on proper machine operation, including safe handling of sharp cutting tools and following lockout/tagout procedures to prevent accidental startup during maintenance.
d) Don’t Overlook Material Handling and Storage
Different materials used in prototyping, from plastics and resins to metals and chemicals, may pose unique hazards if not stored or handled correctly. Improper storage can lead to chemical reactions, material degradation, or fire hazards.
- Do: Store materials like resins, solvents, and chemicals in designated containers and areas that meet safety standards.
- Do: Follow material safety data sheets (MSDS) for guidelines on safe handling and storage of hazardous materials.
- Don’t: Store flammable or volatile chemicals near heat sources, sparks, or open flames.
Example: A team working with flammable resins for vacuum casting should store the resins in a cool, dry location, away from any ignition sources, and handle them with appropriate PPE, such as gloves and respirators.
e) Do Practice Safe Tool Use
Prototyping often involves the use of hand tools, such as drills, saws, or soldering irons. Improper tool use is a leading cause of injuries in workshops, so it’s crucial to follow best practices when using these tools.
- Do: Use sharp blades for cutting and replace any dull or damaged tools immediately to prevent accidents.
- Do: Follow proper soldering safety techniques, including using heat-resistant gloves and ensuring the area is well-ventilated.
- Don’t: Leave tools unattended or within reach of people not trained to use them.
Example: A designer soldering electronic components for a prototype should wear heat-resistant gloves and goggles, and work on a heat-resistant mat to prevent burns or fires.
f) Don’t Skimp on Fire Safety
Prototyping with high-powered machines, heated components, or flammable materials can pose fire risks if not managed properly. Having the right fire safety equipment on hand and following fire safety protocols can prevent small accidents from becoming major incidents.
- Do: Keep a fire extinguisher rated for electrical and chemical fires nearby, especially when working with flammable materials like solvents or in environments with lasers.
- Do: Ensure electrical wiring and power sources are in good condition and aren’t overloaded by machines or equipment.
- Don’t: Leave heated components or machines running unattended, especially overnight.
Example: A company using laser cutters and CNC machines should ensure electrical wiring is up to code, power cords are inspected regularly, and fire extinguishers are easily accessible in the workspace.
g) Do Keep the Workspace Organized and Clean
An organized workspace is a safer workspace. Keeping your area clean and free from clutter helps reduce the risk of tripping, accidental spills, and misplaced tools that could cause injury. Proper disposal of waste materials, such as used chemicals, scrap metal, or plastic, is also critical.
- Do: Clean up spills immediately and ensure that tools and materials are stored properly when not in use.
- Do: Dispose of hazardous waste according to local regulations to prevent environmental contamination or health hazards.
- Don’t: Allow debris, offcuts, or unused materials to accumulate around machines or walkways, where they could create hazards.
Example: A prototyping lab using multiple 3D printers and CNC machines should implement a strict cleaning schedule, ensuring that scrap material and waste are disposed of daily, and workstations are kept free of clutter.
3. Safe Prototyping Practices by Method
Different prototyping methods come with their own specific safety concerns. Here are some guidelines tailored to common prototyping processes:
a) 3D Printing (FDM, SLA, SLS)
- Wear PPE: FDM and SLA printing may involve exposure to hot extruders and toxic resins, so gloves, goggles, and respirators should be used as necessary.
- Ventilate: Ensure the workspace is properly ventilated, as many 3D printing materials release fumes during the printing process.
- Handle Resins Safely: SLA printing resins can be harmful if they come into contact with skin or are inhaled. Use nitrile gloves and avoid direct exposure.
b) CNC Machining
- Guard Moving Parts: Always ensure that moving parts are guarded and that tools are properly clamped before machining.
- Wear Ear and Eye Protection: CNC machines are loud and can produce flying debris, so earplugs and safety goggles are a must.
- Follow Lockout/Tagout Procedures: To avoid accidental machine startups, use lockout/tagout when performing maintenance.
c) Laser Cutting
- Wear Laser-Safe Goggles: Different types of lasers (CO2, fibre) require specific goggles to protect your eyes from damage.
- Avoid Flammable Materials: Be mindful of using flammable materials like paper, fabric, or acrylic without adequate ventilation and fire precautions.
- Supervise the Process: Never leave a laser cutter running unattended, as materials can ignite quickly.
d) Vacuum Casting and Resin Work
- Protect Skin and Eyes: Always wear gloves, goggles, and protective clothing when working with casting resins, which can cause chemical burns or allergic reactions.
- Dispose of Waste Properly: Unused resin, cleaning solvents, and waste should be disposed of in accordance with local environmental regulations.
4. Responding to Accidents and Emergencies
Despite taking all precautions, accidents can still happen. It’s important to have an emergency plan in place and ensure that everyone in the workspace knows how to respond.
- First Aid Kit: Keep a well-stocked first aid kit in the workspace and ensure that team members know where it is and how to use it.
- Emergency Procedures: Have clear protocols for responding to fires, chemical spills, or injuries, including how to shut down equipment and contact emergency services.
- Training: Regularly train employees and team members on emergency response procedures, including how to use fire extinguishers, eyewash stations, and first aid kits.
Final Thoughts: Prototyping Without the Hazards
Prototyping is an exciting and rewarding process, but it’s essential to prioritize safety at every step. By following these do’s and don’ts, ensuring proper use of PPE, maintaining a clean workspace, and adhering to machine and material safety protocols, you can minimize risks and create a safer environment for everyone involved.
Ready to prototype safely and efficiently? Check out our blog for more tips on prototyping techniques, machine safety, and best practices to bring your ideas to life without compromising on safety. Don’t forget to subscribe for updates on the latest tools and innovations in the world of product development!