ORNL Develops First 3D Printed Rabbit Capsule for Reactor Testing

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Are you ready to witness a breakthrough in reactor testing, courtesy of additive manufacturing? Researchers at Oak Ridge National Laboratory (ORNL) have achieved a significant milestone by designing, 3D printing, and testing a specialized specimen capsule for use in their High Flux Isotope Reactor (HFIR). This innovative achievement marks a first for additive manufacturing in the context of reactor components.

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Table of Contents

The Era of Additive Manufacturing in Nuclear Research

The ORNL breakthrough showcases the potential of 3D printing in creating complex shapes more efficiently and cost-effectively than traditional fabrication methods. By employing laser powder bed fusion, the team successfully fabricated a stainless steel rabbit capsule, a type of container used for holding experiments during irradiation inside a test reactor.

Complexity Made Easy with Additive Manufacturing

The 3D printed specimen capsule’s intricate design would have been challenging to produce using traditional methods. However, the use of additive manufacturing allowed the researchers to exploit the design flexibility provided by this technology. This flexibility enabled them to create a capsule that withstood nearly a month in a high neutron flux environment, demonstrating the durability and reliability of 3D printed components under extreme conditions.

3D Printed Component	Material	Fabrication Method
Rabbit Capsule	Stainless Steel	Laser Powder Bed Fusion

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3D Printing in Nuclear Power Applications: A Growing Trend

The use of 3D printing in nuclear power applications is gaining traction. In 2024, Westinghouse Electric Company, a leading nuclear power technology firm, advanced the use of 3D printing in reactor component design by developing filtering bottom nozzles. These nozzles were designed to improve debris capture and fuel endurance in Pressurized Water Reactors (PWRs). By utilizing additive manufacturing, Westinghouse achieved enhanced design flexibility that reduced the diameter of debris capable of entering the reactor, resulting in a 30% increase in resistance to debris-related wear.

The Benefits of Additive Manufacturing in Nuclear Power

The adoption of 3D printing in nuclear power applications offers several benefits, including:

Enhanced design flexibility
Improved component performance
Increased safety
Reduced costs and development times

Ultra Safe Nuclear Corporation’s (USNC) Adoption of Additive Manufacturing

In 2022, Ultra Safe Nuclear Corporation (USNC), a leader in microreactor development, invested in Desktop Metal’s X-Series 3D printers. These printers, capable of processing advanced materials like silicon carbide, support the creation of Fully Ceramic Micro-encapsulated (FCM) fuel for next-generation reactors. USNC’s adoption of additive manufacturing techniques facilitates the production of complex reactor components, enhancing safety and performance in advanced nuclear systems.

The Future of Nuclear Power: A Shift Towards Additive Manufacturing

As researchers and companies continue to explore the potential of 3D printing in nuclear power applications, we can expect to see a shift towards the adoption of additive manufacturing in the industry. This shift will likely be driven by the benefits offered by 3D printing, including enhanced design flexibility, improved component performance, and increased safety.

Oak Ridge National Laboratory’s (ORNL) Plans for Additive Manufacturing

ORNL plans to continue exploiting the design flexibility provided by additive manufacturing to create more intricate components that traditional methods struggle to produce. This effort supports meeting stringent material composition and qualification standards while potentially reducing costs and development times. Post-irradiation evaluation of the 3D printed rabbit capsule is scheduled for this winter, and findings from this analysis could extend the use of 3D printing in safety-critical nuclear applications and other regulated industries.

The Path Forward: Embracing Additive Manufacturing in Nuclear Research

As the use of 3D printing in nuclear research continues to grow, we can expect to see significant advancements in the field. By embracing additive manufacturing, researchers and companies can create complex components with enhanced design flexibility, improved performance, and increased safety. As the industry continues to evolve, one thing is certain – the future of nuclear power will be shaped by the innovative use of 3D printing.

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