⚛️🏗️🔬⚙️ORNL’s New Hybrid Manufacturing Breakthrough for Advanced Nuclear Reactors
ORNL Develops Hybrid Manufacturing Method for HIP Cans and Advanced Nuclear Reactor Components
Oak Ridge National Laboratory (ORNL) is exploring an innovative hybrid manufacturing approach for hot isostatic pressing (HIP) cans, potentially opening a faster and more efficient path for producing complex components used in advanced nuclear reactors.
Working with A.J. Tuck Company, ORNL researchers have developed a process that combines 3D printing, electroforming, and powder metallurgy hot isostatic pressing (PM-HIP). The goal is to simplify the manufacturing of high-precision metal components while reducing production time, material waste, and costs.
What Is a HIP Can?
Hot isostatic pressing is a manufacturing process used to transform metal powder into dense, solid components. Metal powder is placed inside a hollow container, known as a HIP can, which is then sealed and subjected to high temperatures and pressure.
The challenge is that manufacturing HIP cans for complicated shapes can require multiple fabrication, assembly, and welding steps.
ORNL’s hybrid approach could make that process significantly easier.
How ORNL’s Hybrid Manufacturing Process Works
Instead of manufacturing the HIP can entirely through conventional metalworking techniques, researchers begin by 3D printing a polymer form in the required geometry.
The printed form is placed into an electrolyte bath, where electroforming creates a dense nickel shell approximately 2–3 millimeters thick around it.
Next, the polymer material is dissolved, leaving behind a hollow nickel HIP can. Metal powder can then be loaded inside, sealed, and processed using hot isostatic pressing to create the final solid metal component.
One major advantage is that polymer 3D printing avoids some of the material stresses and distortion associated with directly printing large metal components.
Successful Proof-of-Concept Testing
The research team has already demonstrated the concept by manufacturing five leak-free cylindrical HIP cans, each approximately six inches tall and four inches in diameter.
Researchers also developed an integrated port design that removes the need to separately weld process tubes onto the HIP can. Because welded connections can become potential failure points during HIP processing, eliminating this step could improve reliability while simplifying production.
Why This Matters for Advanced Nuclear Energy
Advanced nuclear reactors require components capable of operating under demanding conditions. Manufacturing large, complex, high-precision metal parts efficiently remains an important challenge for the industry.
ORNL’s hybrid manufacturing technology could eventually support components including reactor pressure vessels, valves, impellers, and turbine systems.
The technology may also help strengthen domestic nuclear manufacturing capabilities and reduce supply-chain challenges associated with producing specialized reactor components.
Researchers are now working to demonstrate the process with more complicated geometries, including valves and impellers.
The Future of Nuclear Manufacturing
Combining additive manufacturing, electroforming, and hot isostatic pressing demonstrates how modern manufacturing technologies could transform the nuclear energy supply chain.
If the technique successfully scales to larger and increasingly complex components, it could provide manufacturers with a flexible new method for producing next-generation nuclear reactor hardware.
As advanced reactors move closer to deployment, innovations like ORNL’s hybrid HIP-can manufacturing process could play an important role in making nuclear components faster, more efficiently, and potentially at lower cost.
