Polytetrafluoroethylene (PTFE)-based composites, such as RT-duroid laminates, are widely used due to their exceptional properties. However, working with PTFE composite materials requires awareness of safety precautions during handling, machining, and disposal.

1. General Safety Considerations

• Inert Material Properties:
  PTFE is chemically inert and stable under normal conditions, making it non-toxic in its solid state. However, machining or heating can pose risks.

2. Precautions During Machining

1. Dust and Particulate Control:
   • Risk: Machining PTFE can produce fine dust that may cause respiratory irritation.
   • Precaution: Use localized dust extraction systems and wear an N95 or P3-rated dust mask.
2. Sharp Tools:
   • Risk: PTFE’s softness can lead to uneven cuts, increasing the chance of accidents.
   • Precaution: Use sharp, carbide- or diamond-coated tools for precision.
3. Static Charge Accumulation:
   • Risk: PTFE is an excellent insulator, and machining may generate static electricity.
   • Precaution: Use grounding straps or anti-static measures to mitigate static discharge risks.

3. Precautions During Heating

1. Decomposition Products:
   • Risk: When heated above 260°C (500°F), PTFE begins to degrade, releasing toxic fumes, including hydrofluoric acid (HF) and fluorinated gases. Prolonged exposure to these fumes can cause polymer fume fever, a flu-like illness.
   • Precaution:
     • Ensure proper ventilation (use fume extraction systems).
     • Avoid heating PTFE beyond recommended operating temperatures.
     • Wear appropriate personal protective equipment (PPE), such as respirators with filters rated for acid gases.
2. Open Flames:
   • Risk: PTFE is non-flammable but may degrade under direct flame exposure, releasing hazardous by-products.
   • Precaution: Keep PTFE away from direct flame and excessive heat sources.

4. Handling Adhesives and Coatings

1. Chemical Exposure:
   • Risk: Surface treatments for PTFE may involve strong chemicals or acids.
   • Precaution:
     • Wear gloves, goggles, and chemical-resistant aprons.
     • Follow the material safety data sheet (MSDS) instructions for adhesives or coatings.

5. Disposal and Environmental Considerations

1. Non-Biodegradable:
   • PTFE is non-biodegradable, requiring proper disposal to avoid environmental harm.
2. Incineration Risks:
   • Risk: Incinerating PTFE generates toxic fumes, including HF and other fluorinated compounds.
   • Precaution: Dispose of PTFE materials through certified hazardous waste management facilities.

6. Emergency Measures

1. Exposure to Fumes:
   • Move to fresh air immediately.
   • Seek medical attention if symptoms (e.g., fever, cough, shortness of breath) develop.
2. Contact with Dust or Chemicals:
   • Rinse affected skin or eyes with plenty of water for 15 minutes.
   • Remove contaminated clothing.
3. Fire Situations:
   • Use dry chemical, foam, or CO₂ extinguishers for associated fires.
   • Avoid water as it may spread toxic residues.

7. Best Practices Summary

• Always work in a well-ventilated area.
• Use protective equipment such as gloves, masks, and goggles.
• Avoid overheating PTFE composites.
• Follow local regulations for disposal and recycling.