This study aimed to characterise three titanium powders used in powder bed fusion in terms of particle size, shape, and elemental composition for comparison with safety data sheet (SDS) information, and their relevance to additive manufacturing (AM) operators’ respiratory health. Thoracic (< 10 μm) and respirable (< 4 μm) particles were present in the virgin and used powders. If inhaled, these particles have the potential to cause adverse health effects. Discrepancies in particle size and elemental composition compared with what was declared in the SDSs were found. The SDSs provided insufficient information, which places AM operators’ health at risk. Recommendations for promoting AM operator health are provided.