A new partnership between 3D Systems and Savannah River National Laboratory (SRNL) is applying artificial intelligence to 3D printing technology for nuclear energy, aiming to solve one of the industry's biggest manufacturing challenges: creating complex reactor components faster and more efficiently than traditional methods allow. The collaboration, structured through a Cooperative Research and Development Agreement (CRADA) and centered at SRNL's Advanced Manufacturing Collaborative, represents a significant shift in how the nuclear industry approaches component production as demand for small modular reactors (SMRs) accelerates globally.

Why Does Nuclear Manufacturing Need 3D Printing?

Traditional manufacturing methods struggle with the extreme demands of nuclear components. Reactor parts must withstand intense heat, radiation exposure, and mechanical stress while featuring intricate internal geometries that are nearly impossible to produce using conventional techniques. Heat exchangers with complex cooling channels, reactor internals, pumps, and valves represent the kinds of components that benefit most from additive manufacturing, also known as 3D printing.

The partnership will focus on developing advanced materials and processes specifically designed for nuclear applications. Key areas of investigation include high-temperature nickel-based superalloys and radiation-tolerant materials that can maintain their structural integrity in extreme environments. By enabling engineers to create geometries that would be difficult or impossible to produce traditionally, 3D printing also reduces material waste and provides greater design freedom for demanding operating conditions.

How Is AI Changing the Manufacturing Process?

The real innovation lies in integrating artificial intelligence and machine learning into the manufacturing workflow. Rather than relying on static production parameters, AI-enabled systems can monitor and adjust manufacturing conditions in real time during production. This intelligent optimization could significantly reduce defects, improve consistency, and accelerate the path from prototype to production-ready components.

The infrastructure supporting this research is substantial. 3D Systems has already installed advanced equipment at SRNL's Advanced Manufacturing Collaborative, alongside facility upgrades and specialized additive-manufacturing experts. This setup creates a direct pipeline from materials research and experimental manufacturing toward processes that could eventually scale to production-relevant levels.

Steps to Advance Nuclear Manufacturing Through Additive Technology

• Materials Development: Researchers are investigating high-temperature nickel-based superalloys and radiation-tolerant materials that can withstand the extreme conditions inside nuclear reactors without degradation over decades of operation.
• AI-Driven Process Optimization: Machine learning systems monitor production parameters in real time, automatically adjusting temperature, pressure, and other variables to ensure consistent quality and reduce manufacturing defects.
• Workforce Pipeline Development: The partnership includes training opportunities for researchers, engineers, and technicians to build a skilled workforce capable of operating advanced additive-manufacturing systems across nuclear, aerospace, defense, and energy industries.
• Supply Chain Resilience: By developing domestic advanced-manufacturing capacity, the collaboration aims to strengthen U.S. manufacturing competitiveness and reduce dependence on foreign suppliers for critical nuclear components.

The timing of this partnership aligns with a critical moment in the nuclear industry. According to the International Energy Agency, global small modular reactor capacity could reach approximately 40 gigawatts by 2050 under current policies, or as much as 120 gigawatts under an accelerated scenario. That explosive growth requires manufacturing methods that can shorten development cycles while producing increasingly complex components reliably.

"This agreement demonstrates the impact and importance of high-quality 3D printing materials and technologies on key industrial markets, particularly energy and national security," said Jeff Graves, president and CEO of 3D Systems.

Jeff Graves, President and CEO, 3D Systems

The broader ambition extends beyond printing individual components. The objective is to develop materials, machines, software, and manufacturing expertise that can move additive manufacturing from laboratory research toward repeatable industrial production. This transition from experimental to industrial-scale manufacturing is essential for the nuclear industry to meet projected demand for SMRs and other advanced reactor technologies.

What Does This Mean for the Future of Nuclear Energy?

The partnership arrives as advanced nuclear technologies drive demand for manufacturing innovation. Thailand, for example, is targeting 9 gigawatts of small modular reactor capacity by 2050 as part of its new 25-year power plan, with the government considering allowing private companies to develop and operate SMRs. Similar momentum is building across Southeast Asia and globally, creating urgent demand for manufacturing methods that can accelerate deployment.

The workforce-development component of the 3D Systems and SRNL collaboration is particularly significant. As the nuclear industry expands, it needs skilled personnel trained in advanced additive-manufacturing systems. By creating a pipeline of trained researchers, engineers, and technicians, the partnership addresses a critical bottleneck that could otherwise slow the deployment of new reactor technologies.

For the U.S. nuclear industry specifically, the collaboration strengthens domestic manufacturing capacity at a moment when the country is preparing to build and renew nuclear capacity at a scale not seen in decades. New construction, refurbishments, reactor restarts, license renewals, and a pipeline of small modular reactors and microreactors are advancing simultaneously, all driven by increasing power demands. Advanced manufacturing methods that reduce development time and improve component reliability could be the difference between meeting those ambitious timelines and falling behind.