Binder Jetting and Refractory Materials: A Winning Combination for the Nuclear Reactors of Tomorrow?

Ultra Safe Nuclear Corporation (USNC) is a U.S. company specializing in nuclear energy. Recently, it signed a partnership with Oak Ridge National Laboratory (ORNL) to use its novel additive manufacturing process to design certain components for nuclear reactors. It will use binder jetting and refractory materials, which are highly resistant to extreme heat and degradation, to create complex shapes quickly and cost-effectively.

USNC has developed a thermal and electrical reactor called the Micro Modular Reactor (MMR). Still in the approval process in the United States and Canada, it is the first reactor to be commercialized that will operate using the principle of nuclear fission. In order to accelerate the development of its products, USNC is turning to additive manufacturing and more specifically to the capabilities offered by ORNL, which is already a major proponent of 3D technologies for the nuclear industry. The laboratory is indeed at the origin of the “Transformational Challenge Reactor Demonstration” (TCR) program, which aims to imagine more efficient energy systems, notably through additive manufacturing.

The Micro Modular Reactor (photo credits: USNC)

The USNC Will Rely on Binder Jetting

The USNC explains that it is used to using silicon carbide to design the core components of its reactors. This is a ceramic known for its resistance to very high heat and radiation, but its machining remains very complex and expensive if you want to design complex geometries. However, by using additive manufacturing, and more specifically a binder jet process combined with chemical vapor infiltration, the USNC should be able to overcome these constraints. In addition, the 3D printing method developed by ORNL would be compatible with refractory materials, which are known to resist extreme temperatures and degradation. Kurt Terrani, executive vice president of the USNC, added, “This is the holy grail of additive, that you can do things faster, that are in geometries that were previously very difficult or impossible with conventional manufacturing methods.” It’s not known, however, which components are planned to be printed.