ORNL and A.J. Tuck 3D Print Nuclear Parts With Hybrid Polymer-Metal Process

Oak Ridge National Laboratory and A.J. Tuck Company have developed a new hybrid additive manufacturing process for nuclear energy components. The method combines polymer 3D printing with electroforming to produce hot isostatic pressing (HIP) cans, which are critical for advanced reactor systems.

How the hybrid process works

The team first 3D prints a polymer mandrel and submerges it in an electrolyte bath. Nickel builds up around the mandrel to form a dense shell roughly 2 to 3 millimeters thick. Acid then dissolves the polymer form, leaving a hollow metal structure. The cavity gets filled with metal powder, sealed, and processed through HIP.

This approach replaces the traditional powder metallurgy HIP method. It offers more design flexibility while cutting material costs and post-processing work usually required with direct metal printing.

What the researchers say

Vanshika Singh, research associate staff scientist at ORNL, said the project proves electroforming can produce leak-free HIP cans for nuclear use. She added that the approach could simplify domestic production of these components and ease supply chain pressures for advanced nuclear systems.

Why it matters

Reactor pressure vessels, valves, and turbine systems all need large, precise metal parts. The hybrid process is well-suited to those applications. In the first project phase, the team produced five leak-free cylindrical HIP cans measuring 6 inches tall and 4 inches in diameter. An integrated port design also removed the need for separate welding of process tubes.

The second phase is already underway. Researchers are now applying the process to more complex geometries, including impellers and valves relevant to nuclear energy systems.