Revision Date: July 1, 2025
Contents
4. Fabrication, Testing, and Use
1. Overview
Many Yale students undertake projects that involve using Tools or working in a Shop. These projects may be part of a course, an independent study, a senior project, faculty-directed research, or extracurricular activities. To minimize risks, certain student projects must undergo a formal safety review before using tools or accessing the Shop.
The primary goal of the safety review is to identify any procedures, activities, or materials that could pose risks to the student or others. Hazards can arise from various factors, such as the student’s training level, the Tools and materials used, and potential risks related to the design and use of the fabricated device. Students and their mentors should have a thorough discussion about these potential hazards.
The second goal is to explore ways to reduce or manage the risks identified. For instance, it may be possible to use Tools from lower Risk Groups (see Procedure 4302 PR.04 Student-Access Shop Safety Controls and Tool Risk Group Classification), which may yield satisfactory results without the need for higher Risk Group Tools. In some cases, the review may recommend outsourcing certain work to a professional Shop rather than having the student produce it.
A third goal of the review is to inform Shop Supervisors about the overall project plan, especially for projects that may place significant demands on the Shop. This process also communicates the intended use of the object the student seeks permission to fabricate, ensuring alignment with Shop policies and resources.
2. Projects Requiring Review
A safety review is required for Undergraduate projects that are not part of a standard course assignment and could pose significant health or safety risks. Reviews should be considered for projects that involve:
- Use of Higher-Risk Tools or Equipment: When a project requires Tools in Tool Risk Groups 2-4 with the potential to cause severe or life-threatening injuries.
- Hazardous Materials or Energy Sources: If the project involves hazardous materials (e.g., toxic, flammable, or corrosive substances) or hazardous energy sources (such as electrical, thermal, or pressurized systems).
- Complex or Unusual Fabrication, Testing, or Use Activities: Projects that require specialized or uncommon methods of fabrication, testing, or use.
- Extremely Heavy or High-Load Materials: Projects involving the handling or movement of extremely heavy materials or designs that will endure high loads.
- Repetitive or Awkward Tasks with Materials or Tools: When a project requires repetitive, awkward, or ergonomically challenging tasks.
- Student’s Limited Experience or Training: If the student has limited experience or training with the required Tools, materials, or processes.
- Designs Involving High-Stress Loads or Moving Parts: Projects that include designs with moving parts or will endure significant stress.
- Projects Involving Custom or Unfamiliar Equipment: If a project involves the use of custom-built, modified, or non-standard equipment.
- Significant Demand on Shop Resources: Projects that will occupy extensive Shop resources, such as large amounts of time, space, or access to special equipment.
- Extracurricular Projects Involving Tool Use: For extracurricular, club, or personal projects, a review confirms that appropriate safety standards are maintained and that students understand their responsibilities.
- Mentor or Shop Supervisor Discretion: If a mentor, instructor, or Shop Supervisor identifies specific safety concerns or questions the student’s preparedness, they may request a safety review to address these issues.
Projects with minimal risks or those that have already taken appropriate safety measures do not require review. Additionally, reviews should be conducted for fabrication activities that meet these criteria, even if they occur outside a shop. Graduate Students are also encouraged to use this safety review process
3. Project Review Procedure
A Student Project/Activity Proposal Form (Form 4302 FR.06 Student Project Safety Review Form) is available on the EHS website and offers additional guidance on conducting reviews. Alternate safety documentation is acceptable, and examples can be obtained from EHS. The Shop Supervisor should keep a copy of the form in the Shop’s records.
For projects meeting the above criteria:
- Independent study or senior requirement projects should be reviewed by the faculty advisor/mentor, the Director of Undergraduate Studies, and the Shop Supervisor. Once approved, a copy of the form should be sent to EHS.
- Course-related or faculty-directed research projects should be reviewed by the instructor or faculty advisor and the Shop Supervisor.
- Extracurricular projects (outside of courses or faculty-directed research) should be reviewed by the Shop Supervisor. If the work occurs outside of a Student-Access Shop, EHS will coordinate review and approval. This may include the relevant Dean (e.g., college, sciences, engineering, or arts). A copy of the form should be sent to EHS to initiate the review process.
Throughout the process, the Shop Supervisor and Faculty Advisor should communicate with the student to identify hazards and recommend changes, if necessary.
If concerns arise about the project’s supervision, hazards, or risk mitigation, approval should be deferred until further information or a review from EHS is obtained. Any project that carries substantial risk should be reported to EHS, even if proper mitigation steps are outlined.
For any safety concerns during the review or project work, please consult EHS or the Shop Safety Committee as needed.
4. Fabrication, Testing, and Use
During the project, the Shop Supervisor will monitor the student’s progress and the quality of work to ensure the student has the necessary skills to safely complete the project. A final safety check by the Shop Supervisor and faculty advisor is required before activating or using the fabricated device. In some cases, the Shop Supervisor or faculty advisor may need to be present whenever the device is tested or used.
Related Resources
4302 Student-Access Shop and Tool Safety Policy
4302 PR.04 Student-Access Shop Safety Controls and Tool Risk Group Classification