The Role of 3D Printing in Shaping Nuclear Energy Infrastructure
The world of nuclear infrastructure is experiencing a remarkable transformation, driven by innovation and cutting-edge technologies like 3D printing.
A ground-breaking collaboration between the Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL), Kairos Power, and Barnard Construction is making waves in the construction of the Hermes Low-Power Demonstration Reactor.
The team has successfully developed large-scale, 3D-printed polymer composite forms designed to cast complex, high-precision concrete structures. This innovation promises to reshape how nuclear energy infrastructure is built, marking a significant leap forward in construction practices.
3D Printing for Nuclear Construction
The collaboration between Kairos Power, Barnard Construction, and ORNL is not just a technological milestone but a game-changer for the nuclear energy sector. The 3D-printed polymer composite forms are a step ahead in a field that has traditionally been reliant on costly and time-consuming steel or wood moulds.
These 3D-printed forms are currently being used in the construction of the Hermes reactor facility, where they are employed to cast large, intricate components of the reactor’s structure. With sections measuring around 10 feet by 10 feet, stacked three units high, the precision and efficiency of these moulds are already proving invaluable for the project.
The use of 3D-printed moulds for construction isn’t just a small improvement in technique; it’s a paradigm shift. These forms enable the construction of geometrically complex components with a high degree of accuracy and in much less time. For example, compared to traditional casting methods, the 3D-printed moulds reduce production timelines dramatically, shifting the time frame from weeks to just a few days.
This speed and precision are not just advantageous for nuclear infrastructure projects but could also have broader applications in other complex construction projects.
A New Approach to Nuclear Energy Infrastructure
At the core of this breakthrough lies the innovative use of 3D printing to create composite forms that can withstand the immense pressures exerted by concrete during the casting process. These forms are not just about geometric precision but also about mechanical resilience.
As ORNL’s Ahmed (Arabi) Hassen, group leader for composites innovation, explains: “It’s not just about getting the geometry right; these forms have to handle tremendous stress while maintaining structural integrity.”
The Janus column demonstration at the Oak Ridge campus is a clear example of this technology in action. This column, designed for the Hermes bioshield — a concrete structure that protects workers by absorbing radiation — represents a crucial step in modernizing nuclear construction. The Janus column is built from the 3D-printed moulds, showcasing the potential of 3D printing to enhance both the speed and safety of nuclear infrastructure construction.
The ability to print these large-scale forms quickly and precisely makes it possible to tackle one of the biggest challenges in nuclear construction: the creation of high-precision components in a cost-effective manner. With traditional methods, building these components would involve costly steel or wooden moulds, each requiring careful construction and potentially introducing inaccuracies. By contrast, 3D-printed forms streamline the process, offering greater flexibility and reducing risk.
Transforming the Construction Process
This leap forward isn’t just about technological achievement; it’s about practical application. The efficiency of 3D printing in nuclear construction has wide-reaching implications. As Ryan Dehoff, director of the Manufacturing Demonstration Facility, puts it: “At ORNL, we’re showing that the future of nuclear construction doesn’t have to look like the past.”
This innovation enables “cast-in-place” construction, allowing for the rapid deployment of concrete components with unique geometries. What once took weeks now takes mere days, dramatically cutting down on both time and cost. And that’s just the beginning. The potential to scale this process to commercial plants will allow for faster construction of future nuclear reactors, driving down costs and speeding up timelines for energy production.
As Kairos Power co-founder Edward Blandford notes: “We’ve had a relationship with MDF since Kairos Power’s formation. They move fast, they think creatively, and they’ve demonstrated that they can deliver transformative results when conventional manufacturing would fall short.”
This partnership is not just about pushing boundaries; it’s about creating a new standard for nuclear infrastructure, one that combines national lab innovation with practical, real-world application.
Strengthening the Supply Chain
This project represents an exciting example of industry collaboration. Partners like Airtech, TruDesign, Additive Engineering Solutions, and Haddy, along with Barnard Construction, have worked together to create a new supply chain for nuclear infrastructure. These collaborations have allowed the team to push the limits of additive manufacturing, adapting the technology to meet the unique demands of nuclear construction.
Barnard Construction’s role in this collaboration has been vital, providing real-time feedback, adapting the 3D-printed formwork, and incorporating design changes on the fly. This ability to iterate and refine the design rapidly has played a significant part in the success of the project. “It’s a real example of national lab innovation in action,” says Dehoff, highlighting the strength of the collaborative approach and the impact it’s had on the project’s progress.
The success of this project is a testament to the power of teamwork and innovation. By combining the capabilities of ORNL, the expertise of Kairos Power, and the practical know-how of Barnard Construction, the partners have developed a solution that will not only revolutionize nuclear construction but also create a model for future infrastructure projects.
A Vision for the Future of Nuclear Energy
The broader vision behind this project is to create a faster, more cost-effective, and safer way to build nuclear reactors. The work being done at Oak Ridge National Laboratory has national implications. The region is home to the largest cluster of nuclear-focused companies in the world, and the successful construction of the Hermes Low-Power Demonstration Reactor will lay the groundwork for Kairos Power’s future commercial plants.
As part of the SM2ART Moonshot Project, the partners aim to continue their work with the Department of Energy’s Advanced Materials and Manufacturing Technologies Office, focusing on expanding the use of 3D-printed forms for radiation shielding and reactor building enclosures. Over the next 18 months, the project will evolve to include full-scale production and the integration of smart manufacturing techniques, digital twins, and data-driven quality control.
Looking to the future, Kairos Power and its partners also plan to reduce material costs by utilizing biocomposite feedstocks derived from timber residuals, which will further enhance sustainability and cost-efficiency. By targeting a 75% reduction in material costs using domestic forest products, this initiative could lead to even greater cost savings, making nuclear energy infrastructure more affordable and accessible.
A New Era of Nuclear Construction
This ground-breaking collaboration is an important step toward modernizing nuclear construction, paving the way for faster, safer, and more affordable nuclear energy projects. The innovative use of 3D printing for nuclear infrastructure is just one example of how advanced manufacturing techniques are being applied to the construction industry.
As the technology continues to evolve, it’s clear that 3D printing has the potential to reshape not only nuclear energy but the entire construction sector, creating new opportunities and redefining what’s possible.
Shaping the Future of Nuclear Energy
The future of nuclear energy construction looks bright, with innovations like 3D printing leading the charge. As this technology continues to evolve, it will not only reduce costs and timelines but also make nuclear energy more sustainable and accessible.
This marks the beginning of a new era in energy infrastructure, one where cutting-edge technologies help meet the growing energy demands of the future.
