Researchers at the University of Maine’s Advanced Structures and Composites Center have demonstrated how a 3D printed nuclear reactor can be built faster and more precisely using the world’s largest polymer 3D printer. The facility produced enormous concrete form liners for Kairos Power’s Hermes reactor, a 35-megawatt nuclear facility currently under construction in Oak Ridge, Tennessee.
The project represents a significant advancement in nuclear construction methodology, addressing the dual challenges of tight deadlines and millimetre-level precision requirements. Each reactor wall section stands 27 feet tall, measures three feet thick, and features complex sinusoidal curves that demand exceptional accuracy. The University of Maine’s Advanced Structures and Composites Center was recommended by the Department of Energy’s Oak Ridge National Laboratory specifically for its capability to meet these demanding specifications.
3D Printed Nuclear Reactor Components
The Advanced Structures and Composites Center’s polymer 3D printer, capable of printing hundreds of pounds of material per hour, produced the longest forms ever manufactured at the facility. The team designed and printed specialised sinusoidal concrete form liners that fit into steel frames, creating the massive radiation-shielding walls required for the reactor.
“There was no margin for error,” explained Susan MacKay, ASCC chief sustainable materials officer. The facility’s scanning and metrology team verified every curve and angle against digital models to ensure accuracy and quality. This hybrid casting system reduced costs, accelerated production, and helped Kairos Power maintain its commercial timeline.
MacKay emphasised the significance of the achievement: “We met a commercial deadline with massive, high-precision components, a feat that felt astonishing for an academic centre. This partnership demonstrates that UMaine’s capability is operating at the speed of industry.”
Advanced Manufacturing Alliance Drives Nuclear Innovation
The work forms part of the Specialized Materials and Manufacturing Alliance for Resilient Technologies (SM²ART), a partnership addressing industry challenges and reducing manufacturing costs through local materials and advanced production capabilities. The alliance brings together the University of Maine and Oak Ridge National Laboratory to strengthen US manufacturing infrastructure.
Ryan Dehoff, director of the Department of Energy’s Manufacturing Demonstration Facility, highlighted the broader implications: “Partnerships like SM²ART give industry a direct path to the tools and talent needed to build the nation’s next generation of energy and defence infrastructure.”
Beyond physical printing, University of Maine researchers are developing digital assurance through the Material Process Property Warehouse (MPPW). This system employs artificial intelligence and machine learning to record and track every step of large-scale additive and convergent manufacturing. By creating a digital thread, the MPPW enables components to be born certified, reducing costs, regulatory delays, and risk for industries including nuclear energy and defence.
The 27-year-old facility operates from a 150,000-square-foot laboratory with 400 staff members and maintains a proven track record of meeting the demanding schedules of private industry.
“It’s an unusual level of performance for an academic institution and a critical advantage as the US seeks to modernise its energy infrastructure.”
– Habib Dagher, ASCC executive director
The California-based Kairos Power is developing next-generation nuclear technology designed to be safer and more efficient than traditional reactor designs. The company’s decision to work with the University of Maine demonstrates how advanced manufacturing techniques are being adopted across the nuclear industry to accelerate construction timelines whilst maintaining stringent safety and quality standards.
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