Freemelt has been awarded a contract by the United Kingdom Atomic Energy Authority (UKAEA) to carry out scalability tests for 3D-printed tungsten components. The aim of the project is to validate the suitability of electron beam powder bed fusion (E-PBF) for the series production of high-temperature components for fusion power plants. The contract is worth around SEK 0.7 million and delivery is planned for the first quarter of 2025.
The project builds on previous feasibility studies carried out by Freemelt in collaboration with UKAEA. These initially examined process development, followed by tests on the application of the technology. The current project will test the scalability of production to assess the repeatability of the E-PBF process and contribute to the qualification of components that could be used in future fusion power plants.
“The fact that we now advance the collaboration to volume production tests of tungsten tiles is an important confirmation that our E-PBF technology meets the demanding requirements in fusion energy. Tungsten is one of the most challenging materials to process, and our technology enables the production of complex components with high quality. This is an opportunity to further strengthen our position in the energy sector,” says Daniel Gidlund, CEO of Freemelt.
Fusion energy could become an abundant source of energy in the long term. Unlike nuclear fission, it does not produce long-lasting radioactive waste. However, extremely high temperatures and resistant materials are required for practical use. International research, including projects by Swedish companies such as Novatron, is attracting increasing attention. Investment in the energy sector is expected to increase from USD 300 billion in 2024 to USD 500 billion by 2030. Fusion research itself received USD 7.1 billion in investment in 2024, funded by government programs and private companies such as Commonwealth Fusion.
Experimental tokamak reactors play a crucial role in validating fusion technology before it can be commercialized. These systems require millions of tungsten components. ITER, the world’s largest experimental tokamak, is estimated to require between 1 and 1.5 million tungsten tiles, while smaller power plants from companies such as Tokamak Energy will require around ten percent of this amount.
The UKAEA is the UK’s national authority for the development and commercialization of fusion energy. It is working with industry and research institutions to develop new materials and manufacturing methods for future fusion power stations. The collaboration with Freemelt is a further step in testing additive manufacturing methods in this area.
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