U.S. Abandons Traditional Steel Production for Nuclear Reactor Components, Embracing Advanced 3D Printing Technologies
In a groundbreaking development for the nuclear energy sector, Kairos Power is using a novel construction method at its Oak Ridge, Tennessee campus to build the nation's first new advanced reactor in decades. This innovative approach, which includes massive, custom-printed molds for pouring concrete, is part of the SM2ART Moonshot Project, a multi-year initiative funded by the DOE and led by MDF and the University of Maine [1].
The SM2ART Moonshot Project is supporting Kairos Power's construction initiatives, with plans to expand to full-scale production of forms for radiation shielding and reactor building enclosures. The project aims to develop printable biocomposite feedstocks from timber residuals, with a goal of reducing material costs by 75% [2].
The construction of the Hermes reactor's components is an alternative to traditional steel or wood forms, using additive manufacturing for "cast-in-place" construction. The primary technical challenge was ensuring the 3D-printed forms had structural integrity to withstand high concrete pressure while maintaining geometric precision [3].
The 3D-printed forms, each roughly 10 feet by 10 feet and stacked three units high to form columns, are being used for the Janus shielding demonstration, a precursor to the forms that will be used to construct parts of the Hermes reactor. Testing the molds on demonstration columns allows the team to refine methods and reduce risk before applying the technique to the main Hermes facility and future commercial plants [4].
The Janus shielding demonstration is a test run for building the Hermes reactor. The Janus column, an element of Kairos Power's novel design for the Hermes reactor's bioshield, demonstrates the future of nuclear construction not having to resemble the past [1].
The technique used for constructing the Hermes reactor's components is gaining popularity in the nuclear energy sector. The United Kingdom Atomic Energy Authority (UKAEA) has commissioned two advanced 3D printing machines for future fusion reactors [5].
Edward Blandford, co-founder and chief technology officer of Kairos Power, stated that MDF has demonstrated the ability to deliver transformative results when conventional manufacturing would fall short [6]. Ahmed (Arabi) Hassen, ORNL's group leader for composites innovation, mentioned new design and printing strategies were required for the structural application [7].
The project will also integrate smart manufacturing techniques, digital twins, and data-driven quality control, further enhancing its efficiency and precision [1]. The Hermes reactor is the first advanced reactor to receive a construction permit from the US Nuclear Regulatory Commission [8]. This revolutionary 3D printing method represents a significant advancement in nuclear infrastructure construction, allowing for faster, more accurate, and flexible building of reactor components.
The SM2ART Moonshot Project, supported by the DOE, MDF, and the University of Maine, is developing printable biocomposite feedstocks from timber residuals for full-scale production of forms used in radiation shielding and reactor building enclosures, aiming to reduce material costs by 75%. The construction of Kairos Power's Hermes reactor, the first new advanced reactor in decades, is using additive manufacturing for "cast-in-place" construction, with robotics creating 3D-printed forms to build the reactor components. This groundbreaking development in nuclear energy technology is gaining popularity in the industry, with the UK Atomic Energy Authority commissioning two advanced 3D printing machines for future fusion reactors. Alongside the project, smart manufacturing techniques, digital twins, and data-driven quality control are being integrated to enhance efficiency and precision. The Hermes reactor, the first advanced reactor to receive a construction permit from the US Nuclear Regulatory Commission, represents a significant advancement in nuclear infrastructure construction, leveraging technology and innovation for faster, more accurate, and flexible building methods.
