You are what you breathe: observing airborne carbon fiber particulates during FFF printing of PA6-CF filament

Abstract

Carbon fiber reinforced filaments are increasingly popular in Additive Manufacturing (AM) due to their enhanced mechanical properties compared to traditional materials like PETG, ABS, and Nylon. However, these materials present challenges, including proper drying requirements and potential fiber transfer to the skin during handling. In this study, microscopic examination of fingertips after handling PA6-CF parts revealed significant fiber transfer, raising concerns about airborne fiber dispersal during printing. This research aims to observe the dispersion of fibers from PA6-CF filament using a Bambu Lab X1C desktop Fused Filament Fabrication (FFF) system. A custom apparatus with filter was developed to capture dispersed fibers during printing experiments. The used filters were then observed for fiber content to draw conclusions. Safety precautions are recommended along with a proposed alternative slicing method to minimize fiber transfer from final parts. This study contributes to a safer working environment for 3D printing enthusiasts and professionals by addressing potential health risks associated with airborne fiber dispersion.