MUSE: The First Star Stellarator With A 3D Printed Casing

Technological progress in energy production, free from reliance on fossil fuels, is undergoing exponential growth, facilitated by the emergence of new energy sources and cleaner processes. Today, we showcase a prime example of such innovation: plasma, a field that has been under study for years and is now experiencing a surge in advancements, largely thanks to additive manufacturing. In essence, plasma represents the fourth state of matter, wielding immense strength yet characterized by instability. To harness and explore its potential, specialized devices like star generators or stellarators, such as the one we highlight today, have been meticulously engineered and constructed.

Researchers at the Princeton Plasma Physics Laboratory (PPPL) have pooled their expertise to create a new type of stellarator generator with permanent magnets and a novel 3D printed housing. MUSE, as this new stellarator is called, is based on a less complex and less expensive production technique that will open up new avenues of study in nuclear fusion power plants. Researchers have turned to the development of MUSE as an enhanced solution for two key reasons. Firstly, they have opted for magnets with simpler geometries, and secondly, 3D printing has enabled the creation of a flawlessly circular casing, perfectly suited for containing the plasma.

Permanent magnets from MUSE (left). The 3D printed housing (right).

The star generators that had been manufactured so far were very expensive because their structure was based on electromagnets with very complex geometries and which needed an additional flow of electricity to create their own magnetic field. However, recent PPPL research has shown that other magnets (permanent magnets), similar to “refrigerator magnets”, could also perform this function under optimal conditions. To support such magnets, a circular structure was needed that would be placed on the outside of the whole and would also be able to withstand the magnetic forces. This is where additive manufacturing came into play.