Background: Additive manufacturing (AM), is a rapidly expanding new technology involving challenges to occupational health. Here, metal exposure in an AM facility with large-scale metallic component production was investigated during two consecutive years with preventive actions in-between. Methods: Gravimetric analyzes measured airborne particle concentrations and filters were analyzed for metal content. In addition, numbers of airborne particles < 300nm were investigated. Particles from recycled powder were characterized. Biomonitoring of urine and dermal contamination among AM operators, office personnel and welders was performed. Results: Total and inhalable dust levels were almost all below occupational exposure limits but ICP-MS showed that AM operators had a significant increase of cobalt exposure compared to welders. Numbers of airborne particles (<300nm) showed transient peaks in the AM facility but were lower than in the welding facility. Particle characterization of recycled powder showed fragmentation and condensates enriched in volatile metals. Biomonitoring showed a non-significant increase of urine metals in AM operators. Dermal cobalt and a trend for increasing urine metals during a work-week year in 1, but not in year 2, indicated reduced exposure after preventive actions. Conclusion: Gravimetric analyses show low total and inhalable dust exposure in AM operators. However, transient emission of smaller particles...
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