Oak Ridge Partners with Kairos Power to Revolutionize Nuclear Plant Construction Through 3D Printing in Knoxville Region

In a significant development hailed as a step toward modernizing the nuclear energy sector, the Department of Energy's Manufacturing Demonstration Facility at Oak Ridge National Laboratory, has partnered with Kairos Power and Barnard Construction to introduce large-scale, 3D-printed polymer composite forms for concrete structures in nuclear facility construction. Tackling the complexities and costs associated with traditional construction methods, these novel forms are already being employed in the construction of the Hermes Low-Power Demonstration Reactor on the Kairos Power campus, positioning it as an influencer for the future of American nuclear infrastructure, according to a statement obtained by Oak Ridge National Laboratory.

The advanced concrete forms are serving as a precursor for the upcoming Janus shielding, with each measuring about 10 feet by 10 feet and stacked three units high to form a column, and a part of this pioneering column form was showcased recently at the East Tennessee Economic Council's Nuclear Opportunities Workshop held in Knoxville, as reported by Oak Ridge National Laboratory. Embracing 3D printing has brought notable reductions in production timelines, proving that complex, high-precision concrete components can now be constructed in a mere fraction of the time previously possible, and unlike the traditional reliance on wood or steel forms, this breakthrough offers a leap in both accuracy and efficiency.

Ryan Dehoff, the director of the Manufacturing Demonstration Facility, emphasized the shift in paradigm stating, "At ORNL, we’re showing that the future of nuclear construction doesn’t have to look like the past," and highlighted the lab's history of ambitious, transformative projects in manufacturing, as he told Oak Ridge National Laboratory. Kairos Power has been quick to adopt the rapid learning cycles facilitated by MDF's hands-on approach, and Edward Blandford, Kairos Power’s co-founder and CTO, expressed the advantage of this collaboration, underscoring the lab's pace and creativity as key to delivering results when traditional methods come up short.

In embracing these 3D-printed forms, Kairos Power is not only streamlining construction but also de-risking early regulatory engagement. The project stands as a testament to the innovative fusion of advanced manufacturing techniques and the nuclear energy sector, and it's been made possible by support from industry partners such as Airtech, TruDesign, Additive Engineering Solutions, and Haddy, alongside funding from DOE's Advanced Materials and Manufacturing Technologies Office, according to Oak Ridge National Laboratory. The collaboration taps into ORNL's expertise in materials science, supercomputing, artificial intelligence, and additive manufacturing, with the University of Maine providing large-scale 3D printing prowess and a vision to employ biocomposite feedstocks for more cost-effective future reactors.

The initiative, dubbed the SM2ART Moonshot Project, guided by MDF and the University of Maine, aims to redefine the logistics of nuclear reactor construction. Over the coming 18 months, this endeavor will expand to include complete form productions for radiation shielding, engaging smart manufacturing techniques, digital twins, and data-driven quality control, bringing about innovations with an eye on a sustainable future, as detailed by Oak Ridge National Laboratory. With these strides, Kairos Power not only fortifies the Knoxville-Oak Ridge region's status as a nuclear industrial nexus but pushes the envelope in how the U.S. meets its swelling energy requirements.