ORNL Wins Award for 3D Printed Nuclear Molds

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May 3, 2026 News 10037

A research team at the U.S. Department of Energy's Oak Ridge National Laboratory (ORNL) has won the 2026 SME Additive Manufacturing Case Study Award for using large-format additive manufacturing (LFAM) technology to produce high-precision concrete molds for advanced nuclear reactors.

In nuclear power plant construction, concrete structures—especially radiation shielding components—can account for up to 60% of schedule risk. The ORNL team, collaborating with industry partners like Kairos Power, successfully used LFAM technology to print composite molds for biological shielding columns and radiation shielding wall panels. Some of these wall panels are up to 8.2 meters long and feature complex interlocking joints, which help reduce on-site grouting work.

These molds are designed from digital models, printed in sections, then machined and sealed, achieving tolerances on critical surfaces within 1.6 millimeters and capable of withstanding the pouring pressure of wet concrete up to 3.7 meters high.

"Construction has been a major bottleneck for advanced reactors," said ORNL project lead Ahmed Hassen. "We've shown that digital manufacturing can cut construction timelines by weeks while still meeting the rigorous standards required for nuclear power." Traditional steel molds typically take six to eight weeks to produce, while the ORNL team completed the design, printing, and delivery of reusable molds in about two weeks. After multiple casting cycles, these molds showed no measurable loss in mass.

The ORNL team is currently in discussions with a U.S. large-scale precast concrete manufacturer to promote broader application of this technology. Hassen noted that this project demonstrates additive manufacturing isn't just for prototyping—it can be a reliable, repeatable system for building critical nuclear infrastructure that supports national energy security.