Oak Ridge National Laboratory develops new nuclear manufacturing process

Scientists at the Oak Ridge National Laboratory (ORNL), in collaboration with the A. J. Tuck Company, have developed a hybrid manufacturing process designed to strengthen domestic nuclear manufacturing capacity. The method combines 3D printing with electroforming to produce complex, leak-free hot isostatic pressing (HIP) cans.

These sealed metal containers are essential for consolidating metal powders into high-performance components using extreme heat and pressure. The process involves using a 3D-printed polymer form to define a shape, applying a dense metal shell via an electrolyte bath through electroforming, and then dissolving the polymer to leave a hollow structure. This approach allows for high precision and intricate geometries while bypassing many challenges associated with traditional forging and casting.

Initial testing successfully produced five leak-free cylindrical HIP cans. The research team is now advancing to more complex geometries, such as valves and impellers used in advanced nuclear reactors and small modular reactors. This innovation aims to reduce reliance on global supply chains, as much of the current capacity for large-scale forging and casting is concentrated outside the United States.