Safety Hazards of Low Cost General-Purpose and Castable Resins
BlueCast Promotes safety in 3d Printing Resin Production and Use
Since the inception of BlueCast Original, our primary focus has been safety, guiding every stage of our research and development process.
In the past few years, affordable resin 3D printers have transformed the world of 3D printing by making it accessible to millions who can now print from the comfort of their homes. This trend has also been seen with model and castable resins. Unfortunately, many low-cost resin manufacturers do not adequately address user safety and have neglected to provide comprehensive safety documentation. This has caused a wave of injuries, misinformation, and confusion within the community, leaving users unsure and worried about the safety measures needed when working with resin.
Our newest castable resins like X-One, X-Filigree, X-10, X-5 have been formulating prioritizing casting performance and and a the same time safety.
Understanding the Polymerization Process
Light-curable resins solidify through a process known as radical polymerization, initiated by exposure to specific wavelengths of light. The photoinitiator absorbs this light and generates free radicals, which then react with the double bonds in the monomers /oligomers, progressively forming a durable polymer network.
Common monomers such as acrylates, methacrylates, and acrylamides play a fundamental role in shaping the final structure of the photopolymer. An optimal blend of monomers, photoinitiators, pigments, and additives is essential for achieving superior performance, particularly in castable resins.
Photoinitiators and Their Risks
In BlueCast resins, the photoinitiator is the only component that may pose a hazard but remains necessary for the polymerization process. Industry-standard photoinitiators include:
TPO (diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide): Highly reactive to 405 nm light, ensuring resin clarity. However, the European Chemicals Agency (ECHA) suspects it may impact fertility and fetal development.
BAPO (bis(2,4,6-trimethylbenzyl)phenol): Used in 3D printing resins and paints, with a water-soluble variant (BAPO-OH) effective in visible light.
Concerns About Bisphenol A (BPA) and its derivates
BPA is a well-known endocrine disruptor, capable of interfering with hormonal balance and causing skin allergies. BPA and similar like Bisphenol A ethoxylate diacrylate are used by many cheap castable resin manufactures. The European Union classifies it as a substance of very high concern. While some BPA-derived monomers have different toxicological profiles, BPA and Bisphenol A ethoxylate diacrylate remain widespread in many castable resins, particularly those produced in Asia. Just use Google and check. At BlueCast, we have completely eliminated BPA and other harmful substances to mitigate health risks. Searching for CAS Number 64401-02-1 (which corresponds to Bisphenol A diglycidyl ether polymer, a common BPA-based epoxy resin) on a Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS) is a reliable method to identify if a product contains BPA or its derivatives.
Acryloylmorpholine (ACMO): A Controversial Additive
ACMO is an inexpensive component that accelerates printing and reduces production costs. However, the Environmental Protection Agency (EPA) has placed restrictions on its use due to significant health concerns:
Health risks: Inhalation and skin exposure may lead to organ damage and reproductive issues.
Regulatory oversight: Its presence must be explicitly declared in safety data sheets (SDS).
Unfortunately, ACMO continues to be used in many resins without proper disclosure in SDS, posing unrecognized risks to users.
Environmental Concerns of ACMO
Beyond its health hazards, ACMO, presents on many model cheap model resins and some competitor castable resins, presents a severe environmental threat. Its permissible discharge limit in wastewater is extremely low—disposing of a single liter of resin containing 50% ACMO safely would require millions of liters of water. Alarmingly, some resins marketed as "water-washable" contain ACMO, contributing to increased environmental pollution. Just check on google for CAS 5117–12–4
Unfortunately, the list of hazardous substances used by resin manufacturers based outside the US, the European Community, and Canada does not end here. Covering all of them would make this blog post far too long. The purpose of this article is to raise awareness among users about the potential risks and, most importantly, to encourage the use of proper precautions.
How BlueCast select the Raw Materials: Balancing Safety and Performance
In the production of BlueCast resins, our research and development team adheres to three core principles:
Precision and castability
Mechanical properties tailored to specific applications
Minimal toxicity
Many 3D printing resins, particularly low-cost options, contain hazardous chemicals. To increase awareness, we examine some commonly used chemicals and their associated risks.
Dangers of Low-Cost model and Castable Resins
While resin-based 3D printing opens new possibilities, it is crucial to understand the risks associated with inexpensive resins:
- Skin and eye irritation: Uncured resins can cause dermatitis and allergic reactions.
- Respiratory issues: Volatile organic compounds (VOCs) emitted during printing can irritate the respiratory system.
- Environmental harm: Some resin components pose severe risks to aquatic life.
- Reproductive concerns: Chemicals such as BPA can disrupt hormones and affect fertility.
- Carcinogenic potential: Prolonged exposure to certain chemicals increases cancer risks, especially through inhalation of vapors.
- The hazards of castable resins persist beyond printing, resurfacing during burnout when chemical residues release harmful fumes.
BlueCast's Company policy: Prioritizing Safety
The use of hazardous substances should be limited to cases where no safer alternatives exist. However, many manufacturers prioritize cost reduction over safety. At BlueCast, we follow a clear strategy: eliminate dangerous substances, minimize risks, and develop castable resins with low toxicological impact—while maintaining superior quality and reliable printability.
To ensure user safety, we strongly encourage reviewing safety data sheets (SDS) and taking appropriate precautions when handling resins.