Oak Ridge National Laboratory develops new nuclear component manufacturing method

Scientists at Oak Ridge National Laboratory (ORNL) and the A. J. Tuck Company have developed a hybrid manufacturing process designed to produce critical components for advanced nuclear reactors. The technique combines 3D printing, electroforming, and hot isostatic pressing (HIP) to create leak-free containers, known as HIP cans, which are used to fuse metal powder into solid components under intense heat and pressure.

The process begins by 3D-printing a polymer mandrel in the desired shape. This plastic form is submerged in an electrolyte bath where electroforming deposits a thin nickel shell around it. Once the plastic core is dissolved, a hollow metal container remains. This container is filled with metal powder and processed through HIP to create a dense, solid part.

This method aims to address limited domestic manufacturing capacity in the United States for large, complex metal components, which often rely on expensive forging and casting facilities located abroad. By using a 3D-printed polymer core instead of metal, the process reduces material costs, avoids heat-related distortion, and simplifies the production of complex geometries.