# Maker Safety Practices > Implements makerspace safety protocols with PPE selection by hazard type, machine-specific safe operating procedures (3D printers, laser cutters, CNC, soldering), and emergency response. - Skill: `paulpas/maker-safety-practices` (Agent Skill) - Install (CLI): `npx skillmds@latest add paulpas/maker-safety-practices` - Raw SKILL.md: https://api.skillmd.com/api/skills/paulpas/maker-safety-practices/raw - Safety review: PASS (external: skill-scanner PASS, skillspector CAUTION) - Works with: Claude Code, Claude.ai, OpenAI Codex - Category: Coding & Dev Tools - License: MIT - Author: paulpas (https://skillmd.com/u/paulpas) - Updated: 2026-09-17 - Page: https://skillmd.com/skills/paulpas/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:** | Hazard Type | Sources | Primary Risk | |-------------|---------|--------------| | **Thermal** | Laser cutter optics, soldering iron (300-450°C), 3D printer hot end (200-260°C), heated bed (60-110°C), CNC spindle friction | Burns, fires from ignition of nearby materials, thermal runaway in printers | | **Mechanical** | CNC mill rotating tool, drill press chuck, table saw blade, belt drives, conveyor belts | Lacerations, amputation, eye injury from flying debris, entanglement | | **Chemical** | ABS printer fumes (styrene), solder flux fumes, acetone/Isopropyl alcohol for cleaning, resin printers (uncured photopolymer), spray adhesives | Respiratory irritation, chemical burns, long-term carcinogenic exposure, skin sensitization | | **Electrical** | Mains-powered tools, LiPo batteries (fire/explosion risk), laser tube high voltage (10-30kV DC), soldering station ground loops | Electric shock, electrocution, arc flash burns, LiPo fire and toxic gas release | | **Particulate** | Wood dust from CNC/laser cutting, sanding dust, metal shavings from milling, 3D printer ultrafine particles (UFPs) | Respiratory disease (asthma, silicosis from silica-containing materials), eye irritation, surface contamination | **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:** | Hazard | Required Protection | Standard | Notes | |--------|--------------------|----------|-------| | General workshop work (3D printer, soldering bench) | ANSI Z87.1 safety glasses with side shields | ANSI/ANSI Z87.1-2020 | Must have "Z87" or "Z87+" etched into lens | | CNC milling (flying chips), table saw | Full face shield OVER safety glasses | ANSI Z87.1-2020 + Z87 side shields | Face shield alone is NOT sufficient — secondary eyewear required underneath | | Laser cutter operation | Interlock enclosure OR laser-rated goggles matched to wavelength | EN 207/EN 206 or equivalent | Goggles must have optical density rating for specific laser wavelength (e.g., OD5+ at 1064nm for fiber lasers) | | Chemical handling (resin, acetone) | Splash-proof safety goggles (sealed) | ANSI Z87.1-2020 | Regular safety glasses do NOT prevent splash exposure to eyes | **Hand protection:** | Hazard | Required Protection | Notes | |--------|--------------------|-------| | Chemical handling (resin, acetone, solvents) | Nitrile gloves (minimum 4 mil thickness) | Replace immediately if torn or saturated; latex causes allergic reactions in many people | | Sharp edges (laser-cut sheet metal, raw stock) | Cut-resistant gloves (ANSI Level A3+) | Must be removed before approaching any rotating machinery — loose material can get caught | | Hot surfaces (removing prints, handling heated parts) | Heat-resistant gloves (Kevlar or leather, rated to task temperature) | Do NOT use fabric work gloves near rotating tools | | Electrical work | Class 0 insulated gloves (rated for voltage level) | Must be inspected before each use; rubber inspection certificate required | | General workshop tasks | NO GLOVES near CNC mill, lathe, drill press, or any rotating tool | Glove entanglement causes severe finger/hand amputation — this is the #1 rule of machine safety | **Respiratory protection:** | Exposure | Required Protection | Notes | |----------|--------------------|-------| | Wood dust, sanding, general particulates | N95 respirator (NIOSH-approved) | Must fit-seal check performed each wear; replace when breathing becomes difficult or after 8 hours continuous use | | Solder fumes, light chemical vapors | Activated carbon mask (respirator with organic vapor cartridge) | P100 + OV combination for best protection against both particulates and organics | | ABS printing fumes (styrene), resin vapor, solvent cleaning | Half-face respirator with P100 + OV cartridges | Nuisance masks and cloth masks provide ZERO protection against chemical vapors | | Unknown or high-concentration airborne hazards | Supplied-air respirator (SCBA) or immediate evacuation | Do not enter area — call safety officer or emergency services | **Hearing protection:** | Noise Level | Required Protection | Notes | |-------------|--------------------|-------| | < 75 dB(A) | None required | Normal conversation level | | 75–85 dB(A) | Recommended but not mandatory | Long-exposure monitoring recommended | | 85–100 dB(A) | Earplugs (NRR 25+) or earmuffs | CNC milling, table saws, router tables typically in this range | | > 100 dB(A) | Double protection: earplugs + earmuffs | Chain saws, large industrial saws; limit exposure to < 2 hours/day | **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):** | Check | Action | Pass Criteria | |-------|--------|---------------| | **Emergency stop** | Press the E-stop button, verify machine powers down immediately | Machine stops within 1 second of E-stop actuation; must be physically reset to resume operation | | **E-stop accessibility** | Walk from your normal standing position to the E-stop without moving feet | Path is clear, no cables/tools blocking reach, E-stop is clearly visible and colored red on yellow background | | **Enclosure/interlock (laser)** | Open the laser cutter door while a job is running (if safe to test) or verify interlock engages when door opens | Laser tube immediately ceases emission; status indicator changes from "LASER ON" to "LASER OFF" | | **Ventilation/fume extraction** | Verify exhaust fan is running with airflow indicator active; feel for suction at work zone | Airflow gauge shows adequate flow, or paper strip placed near extraction port is drawn toward it | | **Machine guards (CNC)** | Inspect chip guard is in place, spindle guard intact, axis travel limits functional | Guard covers all exposed rotating tool; limit switches respond when axes reach physical endpoints | | **Thermal runaway protection (3D printer)** | Verify firmware setting is enabled and heater thermistor reads ambient temperature correctly on cold start | Marlin/Motion/RepRapFirmware: "THERMAL RUNWAY PROTECTION" is defined in Configuration.h; hot end does not exceed 50°C without command | | **Grounding** | Inspect power cord grounding pin intact, equipment connected to grounded outlet (no adapters) | Outlet tester shows correct wiring (GROUNDED); no cracked or damaged cords visible | | **Fire suppression readiness** | Fire extinguisher present in room, correct class for hazards, pressure gauge in green zone, inspection tag current | Extinguisher within 30 feet of machine, inspected within last 12 months, type matches workspace hazards (ABC for general) | --- ### 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:** | Material | Fumes Generated | Ventilation Requirement | |----------|----------------|------------------------| | PLA | Minimal (lactide — low toxicity) | Basic room ventilation adequate | | PETG | Glycol-based fumes (low risk) | Room ventilation adequate | | ABS | **Styrene** (carcinogenic, CNS depressant) | **Mandatory: active extraction or outdoor venting. Never run in unventilated bedroom/home office.** | | Nylon | Caprolactam fumes (respiratory irritant) | Active extraction required | | Resin (SLA/DLP) | Uncured photopolymer vapor + UV exposure | **Mandatory: fume extractor, nitrile gloves for handling. Never handle uncured resin with bare skin.** | **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: | Material | Hazard | Why Forbidden | |----------|--------|---------------| | **PVC, vinyl, pleather, "faux leather"** | Chlorine gas release | Produces hydrogen chloride gas — corrodes machine optics, creates toxic cloud, can kill people | | **Polycarbonate (Lexan)** | Melts, ignites | Does not cut cleanly; catches fire inside enclosure | | **HDPE / PP plastics** | Melts through, ignites | Low melting point causes material to drip and ignite | | **Fiberglass** | Silica dust, toxic fumes | Destroys laser mirror and optics with conductive dust | | **Carbon fiber** | Toxic fumes, electrical conductivity | Carbon dust is conductive — can short laser tube electronics | | **Materials with halogenated flame retardants** | Unknown toxic gas release | Chemical composition varies by batch — unpredictable hazard | | **Reflective metals (bare copper, brass, aluminum)** | Laser reflection back into tube | Reflected beam can destroy laser source and create fire | **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:** | Operation | Requirement | |-----------|-------------| | **Charging** | Charge on non-flammable surface (concrete floor, metal tray). Never charge on wood, fabric, or plastic table top. Use a LiPo fireproof bag or sandbox charging station. Maximum charge current: 1C (where C = battery capacity in Ah). | | **Storage** | Store at 3.8V per cell (storage voltage). Keep in fireproof container away from flammable materials. Maximum 5 batteries per container in a makerspace environment. | | **Inspection** | Check every battery before use: no swelling, punctures, or casing damage. A swollen LiPo is CRITICAL — do not charge, do not use. Place in sand bucket and arrange for proper disposal. | | **Disposal** | Deactivate by submerging in salt water solution (10% NaCl by weight) for 48 hours until voltage reads <1V per cell. Then dispose as electronic waste at certified facility. Never place a LiPo in regular trash or recycling. | | **Fire response** | A burning LiPo releases toxic gas (HF, CO). Evacuate the area immediately. Use a Class D fire extinguisher if available; otherwise use copious amounts of sand to smother. Do NOT use water on a lithium fire — it can intensify the reaction. Call fire department even for small fires. | **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) ```python """ 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 ```python """ 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)