Maker Safety Practices

Maker Safety Practices

Implements comprehensive safety protocols for makerspace operations covering hazard assessment, PPE selection by hazard type, machine-specific safe operating procedures for 3D printers/laser cutters/CNC mills/electronics workstations, electrical safety for power tools and battery handling, fume extraction requirements, and emergency response procedures. Safety is not optional — every operation requires a documented risk assessment before the first tool is touched.

TL;DR Checklist

• Complete hazard assessment: identify ALL hazard types (thermal, mechanical, chemical, electrical, particulate) present in the workspace
• Verify PPE matches each identified hazard: ANSI Z87.1 eye protection, N95/respirator for particulates/chemicals, appropriate gloves
• Confirm emergency stop is accessible and functional — within arm's reach, unobstructed, tested before each session
• Ensure fire extinguisher of correct class (ABC general, D for metal fires) is present and inspected within last 12 months
• Verify fume extraction/ventilation is active and functioning BEFORE starting any operation that generates smoke, fumes, or particulates
• Inspect machine safety features: interlocks on laser cutters, chip guards on CNC, thermal run protection on 3D printers, E-stop wiring intact
• Maintain a 36-inch clear workspace perimeter around every operating machine; no flammable materials within that radius
• Confirm first aid kit is accessible within 30 seconds and contains burn dressings, eye wash solution, and trauma supplies
• Wear NO loose clothing, jewelry, or unrestrained long hair near rotating machinery (CNC mills, drill presses, lathes)
• Never leave an active laser cutter, CNC mill, or soldering station unattended — 3D printers may run unattended ONLY if thermal runaway protection is confirmed active and room ventilation is adequate

When to Use

Use this skill when:

• Setting up a new workspace, makerspace bay, or electronics bench before any fabrication begins
• Operating any machine tool (CNC mill, lathe, drill press, saw) for the first time or after maintenance
• Working with materials that generate fumes, smoke, or dust (3D printing ABS, soldering lead-free alloys, cutting composites, sanding wood)
• Handling lithium-polymer (LiPo) batteries for charging, discharging, storage, or disposal
• Performing electrical work involving mains voltage (120V/240V AC) or high-current DC systems
• Conducting soldering operations with any heated tool above 200°C (soldering iron, hot air rework station)
• Preparing for a safety audit or onboarding new makerspace users who need structured safety training
• An incident, near-miss, or unsafe condition has been observed and needs formal documentation

When NOT to Use

Avoid this skill for:

• Situations requiring professional safety officer judgment — industrial-scale chemical storage, radiation equipment, high-voltage (>1000V) systems, confined space entry
• Emergency situations already in progress where immediate action is needed — call emergency services (911 or local equivalent) first, then document using this skill's protocols after the situation is controlled
• Legal compliance documentation for regulated industries (medical device manufacturing, aviation maintenance) — these require certified safety programs and licensed professionals

Core Workflow

Step 1: Assess Hazard Type

Identify every hazard category present in your operation. A single task may involve multiple hazards simultaneously.

Hazard categories and common sources:

Checkpoint: List ALL hazard categories applicable to your specific task. If you can name only one category, you are under-assessing — every operation has at least two hazards.

Step 2: Select Required PPE

Match personal protective equipment to each identified hazard. No single piece of PPE covers all hazards; layer protection appropriately.

Eye and face protection:

Hand protection:

Respiratory protection:

Hearing protection:

Checkpoint: Every identified hazard must have a corresponding PPE requirement listed. If a hazard exists without matched PPE, stop and procure the correct protection before proceeding.

Step 3: Verify Machine Safety Features

Test all safety mechanisms before beginning any fabrication session. A machine with disabled or broken safety features is as dangerous as no machine at all.

Pre-session safety checklist (repeat for every machine):

Step 4: Set Up Safe Work Environment

Configure the physical workspace before activating any equipment.

Workspace layout requirements:

• 36-inch clearance zone: Maintain a minimum 36-inch (91cm) clear perimeter around every operating machine. No stools, bins, cables, or materials within this zone. This provides escape space and E-stop access.
• Flammable material buffer zone: Keep all paper, cardboard, solvents, aerosol cans, and fabric at least 10 feet from laser cutters, soldering stations, and 3D printers with active hot ends.
• Fire extinguisher placement: Class ABC fire extinguisher must be visible and accessible within 30 seconds (approximately 75 feet) of any fabrication station. Class D extinguisher required for any metalworking area.
• First aid kit: Must be stocked within arm's reach (within 30 seconds walking time) and contain: burn gel/dressings, sterile gauze pads, adhesive bandages, trauma shears, eye wash solution, nitrile gloves, and CPR mask.
• Lighting: Minimum 500 lux at the work surface without glare on reflective surfaces (polished metal, laser beam path, mirror-finish prints). Task lamp required for precision soldering or detail sanding.
• Housekeeping: Floor free of tripping hazards (cables routed and taped down), spills cleaned immediately, waste bins with lids for chemical-contaminated materials (acetone-soaked rags stored in sealed metal container to prevent spontaneous combustion).

Step 5: Execute Machine-Specific Safety Protocol

Follow the startup, operation, and shutdown sequence for each machine type. Do not deviate from these sequences.

General startup sequence:

1. Verify workspace is clear (36-inch perimeter, no flammable materials nearby)
2. Confirm PPE is donned correctly for identified hazards
3. Verify ventilation/fume extraction is ACTIVE before powering on the machine
4. Power on machine, allow warm-up period if specified by manufacturer
5. Run a dry cycle or self-test (no material/workpiece loaded) to confirm normal operation
6. Load material/workpiece using appropriate handling tools — not bare hands when hot or sharp
7. Start fabrication — stay within sight of the machine for the first 10 minutes

General shutdown sequence:

1. Allow complete cycle finish — do not abort mid-operation unless an emergency condition exists
2. Wait for all heating elements to cool below safe touch temperature (<50°C)
3. Remove workpiece using appropriate tools (tweezers, pliers, brush — never bare hands on hot parts)
4. Turn off machine power, then disconnect extraction/ventilation after 2 minutes to purge remaining fumes
5. Clean workspace: remove debris, wipe surfaces with appropriate cleaner, store tools in designated locations
6. Log any abnormalities, near-misses, or unusual behavior in the shared incident log

Machine-Specific Protocols

3D Printer Safety

Thermal hazards:

• Hot ends operate at 200–260°C for PLA/PETG/ABS; up to 300°C for Nylon/PC. Contact causes immediate severe burns.
• Heated beds operate at 60–110°C. Contact above 55°C causes second-degree burns within seconds.
• Rule: Never touch a hot end or heated bed without confirming temperature via display or reading <40°C with IR thermometer.

Fume hazards by material:

Thermal runaway protection:

• Must be enabled in printer firmware. Verify before each print session.
• If the hot end temperature exceeds 15°C above the setpoint for more than 10 seconds, thermal runaway should trigger an automatic shutdown and heater disable.
• Test quarterly: disconnect thermistor and verify printer shuts down heaters and alarms within 30 seconds.

Laser Cutter Safety

CRITICAL — Material Incompatibility List:

Never cut or engrave the following materials in ANY laser cutter under any circumstances:

Interlock integrity:

• The enclosure interlock must prevent laser emission whenever the door is open. Test before every session.
• Never bypass or disable an interlock — "I'll just prop it open for this one quick cut" has caused multiple permanent eye injuries in maker spaces.

Ventilation requirements:

• CO2 laser cutters (10.6µm wavelength): Active exhaust fan must move minimum 5 CFM per square foot of bed area, with carbon filter stage for odor removal.
• Fiber lasers (1.06µm): Same airflow requirements PLUS spark extraction for metal cutting operations.

CNC Mill Safety

Tool speed and feed rate verification:

• Before starting any cut, confirm the displayed RPM matches your calculated requirement (see digital-fabrication skill toolpath calculator). Running a small end mill at excessive RPM causes catastrophic tool failure — the tool shatters at high velocity.
• Verify the tool is properly seated in the collet with correct clamping length and torque. A loose tool becomes a high-speed projectile.

Workholding security:

• Vises must be tightened to manufacturer-specified torque before cutting begins.
• Clamps must clear the tool path — verify by jogging the axis manually (low speed) through the full cutting range with the spindle OFF but the light ON for visibility.
• Soft jaws should be used for irregular stock shapes; never rely on friction alone to hold material.

Chip guard and containment:

• The chip guard must enclose all exposed rotating tool surfaces during operation.
• Coolant/minimum quantity lubrication (MQL) systems require splash guards — coolant can create slippery floor hazards.

Electronics / Soldering Station Safety

LiPo battery handling protocol:

ESD protection:

• Wear an ESD wrist strap connected to a common ground point when handling sensitive components (CMOS ICs, FPGA modules, OLED displays).
• Use an ESD-safe mat on the workbench with resistance between 10^6 and 10^9 ohms.
• Store unmounted SMD components in conductive foam or metal containers — antistatic bags are not sufficient for long-term storage.

Fume extraction during soldering:

• Active fume extractor with HEPA + activated carbon filter required within 12 inches of soldering iron tip.
• Soldering in a shared workspace without personal fume extraction is unacceptable — flux fumes affect everyone in the room.
• Lead-free solder (SAC305) produces different fume characteristics than leaded solder (63/37 Sn/Pb) — both require extraction; lead requires additional glove and hand-washing protocols.

Implementation Patterns

Pattern 1: Safety Checklist Generator (Printable Per Machine)

"""
Machine-specific safety checklist generator.

Generates a printable, machine-type-appropriate safety checklist
that can be used for daily pre-session verification or new-user onboarding.
Supports output in plain text, CSV for logging, and structured JSON for digital tracking.
"""

from __future__ import annotations

import json
import csv
import io
from dataclasses import dataclass, field, asdict
from enum import Enum
from typing import Optional


class MachineType(Enum):
    FDM_3D_PRINTER = "fdm_3d_printer"
    SLA_RESIN_PRINTER = "sla_resin_printer"
    CO2_LASER_CUTTER = "co2_laser_cutter"
    FIBER_LASER = "fiber_laser"
    CNC_MILL = "cnc_mill"
    DRILL_PRESS = "drill_press"
    TABLE_SAW = "table_saw"
    SOLDERING_STATION = "soldering_station"
    BENCH_GRINDER = "bench_grinder"


@dataclass
class ChecklistItem:
    """A single safety verification item."""
    id: str                          # Unique identifier, e.g., "3DP-01"
    category: str                    # Hazard type: thermal, mechanical, chemical, electrical, particulate
    description: str                 # Human-readable check description
    pass_criteria: str               # What constitutes a passing result
    is_critical: bool = False        # If True, failure stops all operations


MACHINE_CHECKLISTS: dict[MachineType, list[ChecklistItem]] = {
    MachineType.FDM_3D_PRINTER: [
        ChecklistItem("3DP-01", "electrical", "Power cord and grounding pin intact with no visible damage",
                      "No frayed wires, cracked insulation, or missing ground pin", True),
        ChecklistItem("3DP-02", "thermal", "Thermal runaway protection enabled in firmware",
                      "Configuration.h defines THERMAL_RUNAWAY_PROTECTION_HEATER and THERMAL_RUNAWAY_PROTECTION_BED", False),
        ChecklistItem("3DP-03", "thermal", "Hot end thermistor reads ambient temperature correctly when cold",
                      "Display shows room temperature (18-25C) before any heating command", True),
        ChecklistItem("3DP-04", "thermal", "Heated bed thermistor functional and reading ambient",
                      "Bed temperature display matches room temp within 3C before heating", True),
        ChecklistItem("3DP-05", "particulate", "Room ventilation active during print",
                      "Fan running or window open; ABS prints require dedicated extraction", False),
        ChecklistItem("3DP-06", "chemical", "No flammable materials within 10 feet of printer",
                      "Clear zone verified: no paper, cardboard, fabric, or solvent containers nearby", True),
        ChecklistItem("3DP-07", "electrical", "Emergency stop functional and within arm's reach",
                      "Pressing E-stop immediately cuts power to heaters and steppers; reset required to resume", True),
        ChecklistItem("3DP-08", "particulate", "First-layer adhesion verified before leaving print unattended",
                      "Perimeter fully bonded to bed with no lifting corners observed for at least 2 minutes", False),
    ],
    MachineType.SLA_RESIN_PRINTER: [
        ChecklistItem("SLA-01", "chemical", "Nitrile gloves (4+ mil) worn when handling resin or parts",
                      "No bare skin contact with uncured photopolymer resin", True),
        ChecklistItem("SLA-02", "chemical", "Resin bottles sealed when not actively in use",
                      "Caps tightly closed; no open containers on bench overnight", True),
        ChecklistItem("SLA-03", "particulate", "Fume extraction or dedicated ventilation active",
                      "Extractor running or printing in ventilated enclosure with carbon filter", True),
        ChecklistItem("SLA-04", "chemical", "Spill containment kit available (absorbent pads, sealed container for waste)",
                      "Waste resin and isopropyl alcohol contaminated materials stored in sealed metal container", False),
        ChecklistItem("SLA-05", "chemical", "Eye wash solution accessible within 30 seconds of printer",
                      "Safety goggles and eyewash station within arm's reach of work area", True),
        ChecklistItem("SLA-06", "electrical", "UV light shield intact — no direct UV exposure to skin or eyes",
                      "Printer enclosure closes fully; no gaps allowing UV leakage during print", True),
    ],
    MachineType.CO2_LASER_CUTTER: [
        ChecklistItem("LC-01", "mechanical", "Enclosure interlock tested — laser stops when door opens",
                      "Open door while in standby mode; verify laser emission indicator goes OFF immediately", True),
        ChecklistItem("LC-02", "chemical", "Material compatibility verified — no PVC, vinyl, or halogen-containing materials",
                      "Cutting list checked against prohibited materials table (see digital-fabrication skill)", True),
        ChecklistItem("LC-03", "particulate", "Exhaust fan active and airflow indicator showing adequate suction",
                      "Paper strip at extraction port drawn toward vent; CO2 scrubber/charcoal filter in place if used", True),
        ChecklistItem("LC-04", "thermal", "Fire extinguisher (Class ABC) visible within 30 feet with gauge in green zone",
                      "Extinguisher inspected within last 12 months, pressure needle in green band", True),
        ChecklistItem("LC-05", "electrical", "Focus lens clean and mirror alignment verified",
                      "Lens free of debris/scratches; beam path shows even dot on test paper", False),
        ChecklistItem("LC-06", "chemical", "Compressed air duster canisters stored remotely from laser area",
                      "No aerosol cans within 10 feet — propellants are flammable under laser ignition risk", True),
        ChecklistItem("LC-07", "electrical", "Air assist function verified (keeps lens cool and clears debris)",
                      "Compressed air supply connected, regulator set to specified PSI for material type", False),
    ],
    MachineType.CNC_MILL: [
        ChecklistItem("CNC-01", "mechanical", "All PPE removed before machine operation: no gloves, no jewelry, no loose clothing",
                      "Sleeves rolled above elbows; hair secured; rings/watch/necklace removed", True),
        ChecklistItem("CNC-02", "mechanical", "Chip guard in place and spindle guard intact",
                      "Transparent or solid guard covers all exposed tool surfaces during operation", True),
        ChecklistItem("CNC-03", "mechanical", "Tool properly seated in collet with correct clamping length and verified tightness",
                      "Collet nut tightened with torque wrench to manufacturer spec; tool does not spin by hand", True),
        ChecklistItem("CNC-04", "mechanical", "Workholding secured — vise tightened, clamps clear tool path, soft jaws for irregular stock",
                      "Manual jog through full cutting range with spindle OFF confirms no clamp/tool interference", True),
        ChecklistItem("CNC-05", "electrical", "E-stop functional and accessible without moving feet from standing position",
                      "E-stop button pressed — machine halts within 1 second; requires manual reset", True),
        ChecklistItem("CNC-06", "thermal", "Spindle speed confirmed to match tool material specification before startup",
                      "RPM displayed matches calculated value from toolpath calculator; small end mills not over-runned", True),
        ChecklistItem("CNC-07", "particulate", "Fume extraction or dust collection active for the specific material being cut",
                      "Dust shroud connected to collector; airflow confirmed at work zone", False),
        ChecklistItem("CNC-08", "electrical", "Coolant/MQL system operational and splash guards in place if used",
                      "Coolant level adequate; pump running; no slippery floor hazard from leaks", False),
    ],
    MachineType.SOLDERING_STATION: [
        ChecklistItem("SS-01", "thermal", "Soldering iron/tip temperature set to material-appropriate range (300-380C for lead-free)",
                      "Temperature display reads within 5C of setpoint after 5-minute warm-up", True),
        ChecklistItem("SS-02", "chemical", "Fume extractor active within 12 inches of iron tip with HEPA + carbon filter",
                      "Extractor running; airflow indicator active; filter not past replacement date", True),
        ChecklistItem("SS-03", "thermal", "Iron resting securely in holder when not actively soldering",
                      "Never placed on bench surface; stand is heat-resistant and stable", True),
        ChecklistItem("SS-04", "chemical", "Work area free of flammable solvents during active soldering",
                      "Acetone/isopropyl alcohol containers capped and stored at least 3 feet from station", True),
        ChecklistItem("SS-05", "electrical", "Soldering iron ground connection verified — no voltage on tip relative to ground",
                      "Voltmeter reads <1mV AC between hot iron tip and grounded surface; leakage current <0.5mA", False),
    ],
}


def generate_checklist(machine: MachineType, operator_name: str = "", session_date: Optional[str] = None) -> str:
    """Generate a human-readable safety checklist for the specified machine type.

    Args:
        machine: The machine type to generate checks for.
        operator_name: Name of the operator (for audit trail).
        session_date: Date string; defaults to today if not provided.

    Returns:
        Formatted text checklist ready for printing or digital signing.
    """
    import datetime

    if session_date is None:
        session_date = datetime.date.today().isoformat()

    items = MACHINE_CHECKLISTS.get(machine, [])
    lines = [
        "=" * 70,
        f"  MAKERSPACE SAFETY CHECKLIST",
        f"  Machine Type: {machine.value.replace('_', ' ').upper()}",
        f"  Date: {session_date}",
        f"  Operator: {operator_name or '[NOT SPECIFIED]'}",
        "=" * 70,
        "",
        f"{'#':<4} {'CRIT':<5} {'Hazard':<12} {'Check Description':<45} {'Status':<8}",
        "-" * 76,
    ]

    for item in items:
        crit = "YES" if item.is_critical else "   "
        lines.append(f"{item.id:<4} {crit:<5} {item.category:<12} {item.description:<45} [   ]")

    lines.extend([
        "",
        "-" * 76,
        "RESULT:  PASS (all items checked) / FAIL (any CRITICAL item failed — STOP)",
        "",
        "If any CRITICAL item fails, do NOT operate the machine. Report to safety officer.",
        "Non-critical failures should be logged and corrected before next use.",
        "",
        f"Operator Signature: ___________________________  Time: ___________",
        "=" * 70,
    ])

    return "\n".join(lines)


def generate_checklist_json(machine: MachineType) -> str:
    """Generate JSON format checklist for digital tracking and automated PPE recommendation.

    Returns:
        JSON string with machine checks, hazard categories, and required PPE derived from hazards.
    """
    items = MACHINE_CHECKLISTS.get(machine, [])

    # Derive PPE requirements from the hazard categories present in this machine's checklist
    ppe_required: set[str] = set()
    for item in items:
        if "thermal" in item.category:
            ppe_required.add("heat-resistant gloves (for handling hot parts only)")
            ppe_required.add("ANSI Z87.1 safety glasses")
        if "mechanical" in item.category:
            ppe_required.add("ANSI Z87.1 safety glasses with side shields")
            ppe_required.add("No loose clothing, jewelry, or gloves near rotating tools")
        if "chemical" in item.category:
            ppe_required.add("Nitrile gloves (minimum 4 mil)")
            ppe_required.add("Chemical splash goggles OR respirator with OV cartridges")
        if "electrical" in item.category:
            ppe_required.add("Insulated tools appropriate for voltage class")
        if "particulate" in item.category:
            ppe_required.add("N95 respirator (or P100 + activated carbon for chemical fumes)")

    output = {
        "machine_type": machine.value,
        "checklist_items": [asdict(item) for item in items],
        "required_ppe": sorted(ppe_required),
        "total_checks": len(items),
        "critical_count": sum(1 for item in items if item.is_critical),
    }

    return json.dumps(output, indent=2)


if __name__ == "__main__":
    import sys

    machine_name = sys.argv[1] if len(sys.argv) > 1 else "cnc_mill"
    operator = sys.argv[2] if len(sys.argv) > 2 else ""

    # Map string input to enum
    machine_map = {m.value: m for m in MachineType}
    if machine_name not in machine_map:
        available = ", ".join(sorted(machine_map.keys()))
        print(f"Unknown machine type: '{machine_name}'")
        print(f"Available: {available}")
        sys.exit(1)

    machine = machine_map[machine_name]

    # Generate and display text checklist
    text = generate_checklist(machine, operator)
    print(text)

    # Also generate JSON for digital tracking
    json_out = generate_checklist_json(machine)
    with open(f"checklist_{machine.value}.json", "w") as f:
        f.write(json_out)
    print(f"\nJSON version written to: checklist_{machine.value}.json")

    # Print PPE summary
    ppe_data = json.loads(json_out)
    print(f"\nPPE REQUIRED for {machine.value.replace('_', ' ').title()}:")
    for p in ppe_data["required_ppe"]:
        print(f"  - {p}")

Pattern 2: Hazard Assessment Matrix with Automated PPE Recommendation

"""
Hazard assessment matrix for makerspace operations.

Analyzes the materials, tools, and processes involved in a planned operation
and produces an automated hazard classification with corresponding PPE,
engineering controls, and emergency procedures.
"""

from __future__ import annotations

import json
from dataclasses import dataclass, field
from enum import Enum
from typing import Optional


class HazardCategory(Enum):
    THERMAL = "thermal"
    MECHANICAL = "mechanical"
    CHEMICAL = "chemical"
    ELECTRICAL = "electrical"
    PARTICULATE = "particulate"


class SeverityLevel(Enum):
    LOW = "low"        # Minimal injury risk; first aid sufficient
    MEDIUM = "medium"  # May require medical attention; time off expected
    HIGH = "high"      # Serious injury possible; potential hospitalization
    CRITICAL = "critical"  # Life-threatening; permanent disability or death possible


@dataclass
class HazardEntry:
    """Single identified hazard with severity and mitigation."""
    category: HazardCategory
    description: str
    severity: SeverityLevel
    engineering_controls: list[str] = field(default_factory=list)
    ppe_required: list[str] = field(default_factory=list)
    emergency_procedure: str = ""


@dataclass
class OperationAssessment:
    """Complete hazard assessment for a makerspace operation."""
    operation_name: str
    materials_used: list[str] = field(default_factory=list)
    tools_used: list[str] = field(default_factory=list)
    hazards: list[HazardEntry] = field(default_factory=list)
    required_ppe: list[str] = field(default_factory=list)
    engineering_controls: list[str] = field(default_factory=list)
    emergency_contacts: list[dict] = field(default_factory=list)
    risk_level: str = "low"  # Overall composite risk level


def assess_operation(
    operation_name: str,
    materials: Optional[list[str]] = None,
    tools: Optional[list[str]] = None,
    process_notes: Optional[dict] = None,
) -> OperationAssessment:
    """Run automated hazard assessment for a planned makerspace operation.

    Analyzes the combination of materials, tools, and process details to identify
    all applicable hazards and recommend appropriate controls.

    Args:
        operation_name: Human-readable name of the operation (e.g., "CNC milling aluminum bracket").
        materials: List of material names (e.g., ["6061 aluminum", "WD-40 cutting fluid"]).
        tools: List of tool/machine names (e.g., ["Haas VF-2 CNC mill", "compressed air gun"]).
        process_notes: Optional dict with additional context:
            - "heating": bool — whether heating is involved
            - "high_voltage": float — voltage if electrical work >100V
            - "resin_type": str — photopolymer resin type for SLA printing
            - "metal_powder": bool — whether metal powder handling occurs

    Returns:
        OperationAssessment with complete hazard analysis and PPE recommendations.
    """
    assessment = OperationAssessment(
        operation_name=operation_name,
        materials_used=materials or [],
        tools_used=tools or [],
    )

    materials_lower = [m.lower() for m in (materials or [])]
    tools_lower = [t.lower() for t in (tools or [])]
    notes = process_notes or {}

    # --- Tool-based hazard detection ---
    if any(t in ["cnc", "mill", "lathe", "drill press", "saw", "router"] for t in tools_lower):
        assessment.hazards.append(HazardEntry(
            category=HazardCategory.MECHANICAL,
            description="Rotating tool/spindle presents entanglement and projectile hazards",
            severity=SeverityLevel.HIGH,
            engineering_controls=["Chip guard must enclose all exposed rotating surfaces",
                                   "Workholding verified secure before power-on"],
            ppe_required=["ANSI Z87.1 safety glasses with side shields"],
            emergency_procedure="Hit E-stop immediately; do NOT attempt to free caught material while spindle is moving",
        ))

    if any("laser" in t for t in tools_lower):
        assessment.hazards.append(HazardEntry(
            category=HazardCategory.THERMAL,
            description="Laser beam causes instant blindness and skin burns; enclosure interlock mandatory",
            severity=SeverityLevel.CRITICAL,
            engineering_controls=["Enclosure interlock tested before each session",
                                   "Material compatibility checked against prohibited list (no PVC/vinyl)"],
            ppe_required=["Laser-rated goggles for specific wavelength if operating with door open"],
            emergency_procedure="Shut down laser via E-stop; evacuate if smoke/fire detected; use ABC extinguisher",
        ))
        assessment.hazards.append(HazardEntry(
            category=HazardCategory.CHEMICAL,
            description="Laser-material interaction can release toxic fumes (styrene from ABS, chlorine from PVC, HCN from acrylonitrile)",
            severity=SeverityLevel.HIGH,
            engineering_controls=["Active exhaust ventilation with minimum 5 CFM/sq ft of bed area",
                                   "Carbon filter stage for odor removal"],
            ppe_required=["N95 respirator (minimum); P100 + OV cartridge for known toxic materials"],
            emergency_procedure="Stop cut immediately; vent enclosure before opening door; evacuate if fume alarm triggers",
        ))

    if any("3d print" in t or "fdm" in t for t in tools_lower):
        assessment.hazards.append(HazardEntry(
            category=HazardCategory.THERMAL,
            description="Hot end (200-260C+) and heated bed (60-110C) cause severe burns on contact",
            severity=SeverityLevel.HIGH,
            engineering_controls=["Thermal runaway protection enabled in firmware",
                                   "Print bed mounted with secure attachment"],
            ppe_required=["Heat-resistant gloves for removing prints after cooling period"],
            emergency_procedure="Do NOT touch hot components; wait 10 minutes for cooldown; use IR thermometer to verify <50C",
        ))

    if any("resin" in t or "sla" in t or "dlp" in t for t in to

…(truncated)