Articles tagged with "materials-engineering"
3D printing breakthrough merges multiple materials in one print
Researchers at Oak Ridge National Laboratory (ORNL) have developed a novel extrusion system for large-scale 3D printing that merges multiple smaller extruders into a single high-output material stream using specially engineered nozzles. This innovation overcomes a key tradeoff in extrusion-based additive manufacturing: large extruders provide high volume but reduce precision and add weight, while smaller extruders offer control but lack scalability. ORNL’s modular system allows users to activate or deactivate extruders as needed, scaling output without sacrificing accuracy or increasing the mechanical burden on motion systems. A standout feature of the technology is its ability to print multiple materials simultaneously within a single extrusion bead, eliminating the need for tool changes or separate print passes. This is achieved through patent-pending aluminum bronze nozzle blocks with Y-shaped internal channels that merge molten polymer streams, improving bead quality and doubling material flow. Additionally, a proprietary nozzle design enables core-and-sheath bead structures, combining different polymers to enhance mechanical properties and interlayer adhesion, addressing common
3D-printingadditive-manufacturingmulti-material-extrusionmaterials-engineeringpolymer-compositesmanufacturing-technologyOak-Ridge-National-LaboratorySupersonic shock tests reveal that metals weaken under extreme speeds
Researchers at Cornell University have overturned a long-standing principle in materials science known as the Hall–Petch law, which states that metals become stronger as their internal grain size decreases. Using laser-induced microprojectile impact testing to subject copper samples to supersonic speeds (over 761 mph), the team discovered that, contrary to expectations, metals with smaller grain sizes actually softened under these extreme deformation rates. Larger-grained copper samples exhibited greater hardness and energy dissipation, challenging the conventional understanding that grain boundaries always block dislocation movement and thus strengthen metals. The study attributes this reversal to the behavior of dislocations—microscopic defects responsible for deformation—at ultra-high strain rates. Under normal conditions, grain boundaries impede dislocation motion, strengthening the metal. However, at supersonic deformation speeds, dislocations accelerate enough to interact with vibrating atoms in the metal lattice, a phenomenon called dislocation–phonon drag, which alters the strengthening mechanism. Although the experiments focused on copper, preliminary tests on other
materials-sciencemetal-strengthHall-Petch-lawgrain-sizesupersonic-impactdeformationmaterials-engineeringWearable health devices could generate a million tons of e-waste by 2050
A recent study from Cornell University and the University of Chicago highlights a looming environmental challenge posed by the rapid growth of wearable health devices such as glucose monitors, blood pressure trackers, and fitness trackers. By 2050, global demand for these devices could reach 2 billion units annually—42 times the current volume—potentially generating over a million tons of electronic waste and 100 million tons of carbon dioxide emissions if manufacturing practices remain unchanged. This surge in e-waste and emissions underscores the significant environmental footprint of these increasingly popular gadgets. The study, published in Nature, reveals that the primary environmental impact comes not from the plastic components but from the printed circuit boards (PCBs), which constitute about 70% of the carbon footprint due to the intensive mining and manufacturing of rare minerals used in their production. To mitigate this, researchers recommend two key strategies: designing chips with more common metals like copper instead of rare minerals such as gold, and creating modular devices that allow reuse of the circuit boards while replacing only
IoTwearable-deviceselectronic-wastesustainabilityprinted-circuit-boardscarbon-footprintmaterials-engineeringPhotos: This real-life giant Pokéball fits you and houses a retro gaming sanctuary
The article highlights an ambitious fan-made project by Carlos from “Carlos 3D Worlds,” who constructed a life-sized, 2-meter tall Pokéball that can fit a person inside and serves as a retro gaming sanctuary. The structure combines advanced 3D printing and woodworking techniques, featuring a CNC-cut plywood skeleton covered by 400 individual 3mm-thick 3D-printed panels reinforced with fiberglass and resin. After overcoming material challenges and technical failures, the builder achieved a smooth, glossy exterior through extensive sanding and putty application. The design includes practical features such as a door near the base for easy entry and hidden wheels beneath a green turf mat for mobility. Inside, the Pokéball houses a themed gaming lounge equipped with a Nintendo 64 console connected to a CRT television, framed trading cards, integrated lighting, and custom furniture tailored to the curved interior. A dedicated electrical system powers the hardware and lighting, with an external disconnect plug allowing for easy transport without rewiring. This project
3D-printingmaterials-engineeringfiberglassresinCNC-woodworkingstructural-designfabrication-techniquesMichelle Simmons on why silicon could deliver the first fault-tolerant quantum computer
Michelle Simmons, a physicist trained in the UK and based in Australia, has been a pioneer in atomic-scale silicon electronics, demonstrating the world’s first single-atom transistor in 2012 and the narrowest silicon conducting wires. Her early recognition that silicon could host exceptionally precise and scalable qubits led her to found Silicon Quantum Computing (SQC) in 2017, aiming to commercialize quantum processors built from atomically engineered silicon. Her work has earned significant accolades, including Australian of the Year (2018) and the Prime Minister’s Prize for Science (2023). Simmons emphasizes that her practical skills in semiconductor fabrication and quantum measurement uniquely positioned her to develop quantum devices at the atomic scale. Simmons transitioned from academia to entrepreneurship because, after mastering atomic-scale manufacturing and achieving high-quality qubits, she saw that a company structure was essential to rapidly build a full-scale commercial quantum system. She highlights the transformative potential of quantum computing across industries, as quantum processors (QPUs) will solve complex
quantum-computingsilicon-technologyatomic-scale-electronicsfault-tolerant-quantum-computersemiconductor-fabricationmaterials-engineeringquantum-processorsSolid-state batteries carry fire risks similar to liquid cells: Report
The article discusses the safety risks associated with solid-state batteries, which are often promoted as a safer alternative to traditional liquid lithium-ion batteries. Despite replacing liquid electrolytes with solid ones, experts caution that solid-state batteries still carry significant fire and thermal runaway risks due to their high energy density and the reactive nature of lithium metal, especially in designs using lithium metal anodes. Experimental findings indicate that lithium metal can react with cathode materials even without oxygen, potentially causing extreme aluminothermic reactions at very high temperatures. Thus, safety challenges remain and must be addressed through careful materials engineering, cell design, and manufacturing controls rather than assuming inherent safety. In China, momentum is growing to commercialize solid-state batteries in the automotive sector, with companies like FAW Group planning to introduce these batteries in vehicles by 2027 and others initiating pilot production for testing. However, some analysts warn against viewing solid-state batteries as a guaranteed solution to fire risks, noting that liquid lithium-ion batteries continue to improve in safety through innovations
energysolid-state-batterieslithium-ion-batteriesbattery-safetymaterials-engineeringenergy-storageautomotive-energy-technologyReinvented 300-year-old cello earns US student Shark Tank deal
Elijah Lee, a biomedical engineering senior at Yale and co-founder of Forte3D, has reinvented the traditional cello by using 3D printing combined with carbon fiber and polymer composites. Originating from a high school project, Lee aimed to create a cello that is more affordable, durable, and portable than conventional wooden instruments, which often cost over $5,000 and are fragile. The innovative cello features flat carbon-fiber panels for the top and back, 3D-printed ribs and neck, and retains traditional parts like the sound post and fingerboard to preserve authentic sound quality. Utilizing rapid Computer-Aided Design (CAD), the team can precisely adjust the instrument’s shape and materials to optimize acoustics, surpassing the limitations of carved wood. After six years and hundreds of prototypes, Forte3D’s cello has attracted attention from renowned musicians such as Yo-Yo Ma and The Piano Guys. The company also offers customizable finishes to reflect individual player styles. Forte3D secured a $
3D-printingcarbon-fiberpolymer-compositesmaterials-engineeringmusical-instrumentsadvanced-materialsmanufacturing-innovationPhenomenal Moments: Photographs That Illuminate The Science Behind Our World - CleanTechnica
The article highlights internationally acclaimed science photographer and MIT research scientist Frankel’s new book, *Phenomenal Moments: Revealing the Hidden Science around Us*. The book aims to inspire curiosity and scientific understanding through vivid fine art photographs that showcase the intersection of science and photography. Frankel’s work emphasizes that everyday objects and phenomena have scientific stories behind their appearances, encouraging readers—especially 21st-century teens—to engage with the world around them from a fresh, inquisitive perspective. By combining visual art with scientific explanation, she hopes to make complex concepts like global warming more accessible and foster a deeper appreciation for the natural world. Frankel’s approach is interdisciplinary, reflecting her background in chemical, mechanical, and materials engineering at MIT, and her belief that both scientists and photographers share a creative process of experimentation and discovery. She founded Image and Meaning workshops to promote public understanding of science through visual expression and developed an online MOOC on science and engineering photography available on MIT OpenCourseWare. *Phenomenal Moments
materials-sciencechemical-engineeringmaterials-engineeringscientific-photographyscience-communicationinnovationresearch-scienceUS finishes first nuclear warhead production for new cruise missile
The National Nuclear Security Administration (NNSA) has completed the first production unit of a critical nuclear warhead component, the “canned subassembly” (CSA), for the W80-4 Life Extension Program 18 months ahead of schedule. The CSA, produced at the Y-12 National Security Complex in Tennessee, forms the secondary stage of the thermonuclear W80-4 warhead, which will arm the Air Force’s new Long-Range Standoff cruise missile, replacing the older Air Launched Cruise Missile. This milestone, celebrated on September 22, reflects a rare early achievement in the US nuclear modernization effort, which aims to update aging Cold War-era weapons amid growing global threats. The full W80-4 warhead is expected by 2027, ahead of the Air Force’s planned timeline. The success is attributed to close collaboration between Lawrence Livermore National Laboratory (LLNL), which designed the warhead, and Y-12’s production teams. LLNL scientists and
energynuclear-weaponswarhead-productionmaterials-engineeringdefense-technologymanufacturing-processesnuclear-modernizationUS Navy to add largest-ever 20,800-ton nuclear missile submarines
The Pentagon awarded General Dynamics Electric Boat a $2.28 billion contract on November 17 to support the advanced procurement and construction of five Columbia-class ballistic missile submarines (hulls SSBN-828 through SSBN-832). These submarines represent the next-generation fleet that will serve as the cornerstone of the U.S. sea-based nuclear deterrent for the next 50 years. Work will primarily occur at Electric Boat’s Groton, Connecticut shipyard, with additional activities in Rhode Island and Virginia, coordinated alongside the Naval Sea Systems Command. This contract is part of a long-term effort to replace the aging Ohio-class submarines, which have been the backbone of the U.S. nuclear triad’s sea leg since the 1980s. The Navy plans to field 12 Columbia-class submarines to replace its current fleet of 14 Ohio-class boats, which will begin retiring at a rate of one per year starting in 2027. The Columbia-class subs, the largest ever built for
energynuclear-energysubmarine-technologydefense-technologymaterials-engineeringnaval-engineeringpropulsion-systemsNew solid-state sodium battery design could replace lithium in EVs
Researchers at Western University in Ontario, Canada, led by Professor Yang Zhao, have developed a new solid-state sodium battery design that could offer a cheaper, safer, and more sustainable alternative to lithium-ion batteries commonly used in electric vehicles (EVs) and renewable energy storage. This innovation replaces lithium, which is costly, flammable, and scarce, with sodium—an abundant and inexpensive element. The team addressed a major challenge in solid-state sodium batteries by creating a novel solid electrolyte material composed of sulfur and chlorine, which facilitates efficient sodium-ion conduction while enhancing the material’s stability and strength. Laboratory tests demonstrated that the new electrolyte exhibits high sodium-ion conductivity along with excellent thermal and mechanical resilience, qualities essential for batteries to endure thousands of charge-discharge cycles and extreme temperatures without degradation. Using advanced X-ray analysis at the Canadian Light Source synchrotron, the researchers gained detailed insights into ion movement and bonding within the electrolyte, accelerating material development. Although commercial solid-state sodium batteries remain several years away, this
energysolid-state-batterysodium-batterylithium-replacementelectric-vehiclesmaterials-engineeringenergy-storageLithium-sulfur batteries to offer high performance with new Korean method
Researchers in South Korea have developed a novel dual-level engineering strategy using metal–organic framework (MOF)-derived hierarchical porous carbon nanofibers embedded with low-coordinated cobalt single-atom catalysts (Co–N3 moieties) to significantly improve lithium–sulfur (Li–S) battery performance. This approach addresses key limitations of Li–S batteries, such as the polysulfide shuttle effect, slow redox kinetics, and rapid capacity fading, by enhancing ionic conductivity, electrolyte wettability, and accelerating lithium polysulfide adsorption and conversion. The integration of macro- and atomic-level design optimizes both the carbon substrate structure and catalyst environment, resulting in improved redox kinetics and suppression of polysulfide dissolution. The resulting material is flexible, binder-free, and mechanically robust, suitable for direct application as an interlayer in pouch cells, maintaining integrity even under bending. This advancement paves the way for high-performance Li–S batteries with potential applications in electric vehicles with longer driving
energylithium-sulfur-batteriesmaterials-engineeringmetal-organic-frameworkscarbon-nanofibersbattery-technologyclean-energy-storageBMW, Samsung join hands to back solid-state battery to double EV range
BMW, Samsung SDI, and Solid Power have formed a strategic partnership to advance all-solid-state battery (ASSB) technology for electric vehicles (EVs). Building on BMW and Solid Power’s collaboration since 2022, Samsung SDI brings its expertise in large-scale cell manufacturing and materials engineering to produce ASSB cells using Solid Power’s sulfide-based solid electrolyte. BMW will focus on battery pack and module design. This collaboration aims to develop safer, higher-performance batteries with improved energy efficiency, marking a significant step toward commercial-scale production of ASSBs. Samsung SDI has already launched a pilot production line in South Korea and begun producing prototype solid-state batteries, which have been delivered to customers for evaluation. Meanwhile, BMW conducted successful on-road tests of Solid Power’s ASSB cells in a modified i7 sedan, targeting the introduction of these batteries in production EVs by around 2030. ASSBs promise to double EV driving range and enable faster charging, addressing key limitations of current lithium-ion batteries
energysolid-state-batteryelectric-vehiclesBMWSamsung-SDImaterials-engineeringbattery-technologyHERO’s Mission: Engineering "Video Games" Meet Wave Tank - CleanTechnica
The article discusses the latest developments in the HERO Wave Energy Converter (WEC) project led by the National Renewable Energy Laboratory (NREL), which aims to advance wave energy technology by combining engineering simulations with physical wave tank testing. Since 2024, the team has been improving the HERO WEC’s design to enhance its robustness, reliability, and deployability. Key upgrades include replacing the original wire rope winch line with a polyurethane flat belt and transitioning from an inflatable raft-like outer body to a more rigid, shell-like frame. This redesign addresses the limitations of the initial compact design, which was constrained by shipping size requirements and suitable only for short deployments, by enabling the device to better withstand harsh ocean conditions for longer periods. The HERO WEC operates by pumping seawater through an onshore reverse osmosis system to produce fresh water, using either hydraulic or electrical configurations. To improve maintenance and survivability, power system components have been relocated to the top of the float. Before finalizing these changes,
energywave-energy-convertersrenewable-energydesalinationNRELsimulationmaterials-engineeringCarbon-built Capricorn 01 Zagato hypercar limited to 19 units
The Capricorn 01 Zagato is a limited-edition hypercar developed by German motorsport supplier Capricorn Group in collaboration with Italian coachbuilder Zagato, with only 19 units to be handbuilt in Germany starting in 2026. Priced at €2.95 million (approximately $3.2 million), the car emphasizes analog purity and mechanical engagement in an era dominated by digital technology. It features a supercharged 5.2-liter V8 engine producing over 900 horsepower, paired with a five-speed manual gearbox, and weighs under 1,200 kilograms. This combination delivers a visceral driving experience rooted in motorsport engineering, including a carbon fiber monocoque chassis, double-wishbone suspension, and adaptive dampers tuned for balance and precision. Design-wise, the Capricorn 01 Zagato stands out for its restrained, sculptural aesthetic that prioritizes aerodynamic efficiency without aggressive visual elements. Signature Zagato design cues such as the double-bubble roof and seamless carbon fiber bodywork create
carbon-fiberhypercarmaterials-engineeringautomotive-materialslightweight-materialscarbon-compositemotorsport-materialsNew software helps build 3D objects with smooth material transitions
OpenVCAD is a new open-source software tool developed at the University of Colorado Boulder that revolutionizes multi-material 3D design by enabling engineers to create objects with smooth material gradients through code-driven precision. Unlike traditional CAD tools that define only an object’s outer boundaries and assume a single interior material, OpenVCAD allows users to assign complex mathematical functions to represent spatially varying materials within a 3D object. This capability simplifies the design of gradient objects—such as shoe soles transitioning from firm to soft—by letting users update designs through small code changes rather than redrawing entire models. Created in the Matter Assembly Computation Lab under Assistant Professor Robert MacCurdy and developed by PhD student Charles Wade, OpenVCAD supports multi-material printing with up to five materials simultaneously and has demonstrated versatility across various 3D printers. Its applications extend beyond academia to fields like medical modeling, soft robotics, and structural engineering, where it can help create lifelike anatomical models, flexible robotic actuators, and
3D-printingmulti-material-designadditive-manufacturingCAD-softwarematerials-engineeringcomputational-designgradient-materialsIntel unveils 18A chips in major push to revive US semiconductor edge
Intel has unveiled its most advanced processors to date—the Core Ultra series 3 (codenamed Panther Lake) and Xeon 6+—built on its cutting-edge 18A semiconductor process. Panther Lake targets consumer and commercial AI PCs, gaming, and edge computing, featuring a scalable multi-chiplet architecture with up to 16 new performance and efficient cores, delivering over 50% faster CPU performance than its predecessor. It also includes an Intel Arc GPU with up to 12 Xe cores for 50% faster graphics and supports AI acceleration up to 180 TOPS. Additionally, Intel is expanding Panther Lake’s reach into robotics and edge applications through a new AI software suite and reference board. Xeon 6+, Intel’s first 18A-based server processor, is designed for hyperscale data centers and cloud providers, offering up to 288 efficient cores and a 17% increase in instructions per cycle, with availability expected in early 2026. The 18A process represents a
semiconductorsIntel-18AAI-chipsroboticsedge-computingenergy-efficiencymaterials-engineeringIndian Bus Builder JBM Brings its EV Bus to Busworld 2025 - CleanTechnica
Indian electric bus manufacturer JBM Electric Vehicles made a significant move at Busworld 2025 in Brussels by unveiling its ECOLIFE e12 city bus and announcing the establishment of a European headquarters in Frankfurt. This marks JBM’s transition from merely exporting vehicles to Europe to establishing a local presence, signaling a strong commitment to competing in the demanding European public transport market. JBM is notable as one of only two non-Chinese, non-European bus makers at the event, alongside Vietnam’s VinFast. The company operates what it claims is the world’s largest integrated electric bus manufacturing facility outside China, with an annual capacity of 20,000 units, and has already achieved substantial operational milestones including over 200 million electric kilometers traveled and more than 1 billion passengers transported globally. The ECOLIFE e12 is tailored to meet stringent European standards, featuring a durable yet lightweight 12-meter stainless steel monocoque body, a range of up to 400 kilometers per charge, and ultra-fast charging capabilities
electric-vehiclesenergysustainable-transportationelectric-busesadvanced-driver-assistance-systemsclean-energymaterials-engineeringUS to boost production of dual-thrust rocket motor, key for missiles
The United States is set to accelerate production of the Mk 104 dual-thrust rocket motor, a critical component of the Standard Missile program, through a new $26 million purchase order jointly executed by Raytheon and Avio USA. This order follows a contract signed 13 months earlier for preliminary engineering work and aims to expand the supply chain, enhance production capacity, and ensure the resilience and availability of the Mk 104 motor. The funding will support the project through the Critical Design Review phase, procurement of long-lead materials, and enable increased and faster production of solid rocket motors. The Mk 104 motor is essential for the SM-6 missile system, which integrates three missiles into one unit capable of anti-air, anti-surface, and ballistic missile defense missions, providing versatile sea control capabilities for the U.S. Navy and its allies. Both companies have completed key development milestones, including System Requirements and Preliminary Design Reviews, laying a strong foundation for further qualification and production. This collaboration also involves leveraging
energyrocket-motormissile-technologysolid-rocket-motorproduction-capacitydefense-technologymaterials-engineeringFerrari Lucybelle II reimagined in scale, honoring 1958 Le Mans
Hedley Studios has introduced the Ferrari Testa Rossa J ‘Lucybelle II,’ a meticulously crafted 75 percent scale model honoring the privateer Ferrari 250 Testa Rossa that raced at the 1958 24 Hours of Le Mans. Limited to only three hand-built units, the model faithfully recreates the original car’s distinctive Bianco Cervino paint with blue stripes and No. 22 roundels, presenting it as it appeared after enduring 24 hours of racing—weathered, scarred, and unpolished. This approach celebrates the car’s endurance legacy and character rather than focusing solely on trophies or perfection. The creation process involved close collaboration with Centro Stile Ferrari, using original drawings and historic photographs to ensure authenticity. The body panels are hand-beaten aluminum, and the interior features Ferrari-sourced red leather with white piping, a Nardi steering wheel, and remastered gauges adapted for electric vehicle (EV) use. The model is not just a static display
energyelectric-vehiclebattery-technologyautomotive-engineeringFerrariendurance-racingmaterials-engineeringFirst 3D-printed ion traps hit 98% fidelity in quantum operations
Scientists from Lawrence Livermore National Laboratory (LLNL), in collaboration with UC Berkeley, UC Riverside, and UC Santa Barbara, have developed miniaturized quadrupole ion traps using high-resolution 3D printing, achieving quantum gate fidelities as high as 98%. These 3D-printed ion traps combine the stability advantages of traditional bulky 3D traps with the scalability of planar traps, overcoming a longstanding tradeoff in quantum computing hardware. The traps confine calcium ions at competitive frequencies and error rates, enabling stable ion manipulation, including two-ion position exchanges lasting minutes and high-fidelity two-qubit entangling gates. The use of ultrahigh-resolution two-photon polymerization printing allows rapid prototyping—printing full traps in about 14 hours or just electrodes in 30 minutes—significantly accelerating design iterations and enabling complex hybrid planar-3D geometries. This expanded design flexibility opens new avenues for optimizing and miniaturizing ion traps. The team plans to further
3D-printingion-trapsquantum-computingmaterials-engineeringminiaturizationquantum-informationadvanced-manufacturing1984 Macintosh reborn with 3D-printed case, classic Apple logo
Quinn Nelson of Snazzy Labs has created a modern homage to the 1984 Apple Macintosh by designing a fully 3D-printed case that replicates the original beige computer’s iconic silhouette and rainbow Apple logo. Inside the case, a Raspberry Pi 3B+ powers an emulated classic Mac OS displayed on a 10.5-inch IPS screen that maintains the original 3:2 aspect ratio but offers higher resolution and more usable space. The build integrates vintage Apple Desktop Bus peripherals via a BMOW Wombat adapter, allowing authentic keyboards and mice to connect seamlessly, blending retro hardware with modern technology. The project showcases advanced maker techniques, including color-matched filament printing, a custom 3D-printed tray combining rigid and flexible materials to secure the Raspberry Pi, and a separately printed and finely finished rainbow Apple logo. A playful design element is the corkboard base on the underside of the case, adding practical everyday use to the retro-inspired machine. To foster community engagement and
3D-printingRaspberry-Piretro-computingmaterials-engineeringDIY-electronicscomputer-hardwarefabrication-techniquesNASA needs your help reinventing wheels for Moon rovers
NASA, in collaboration with HeroX, has launched the “Rock and Roll with NASA Challenge,” inviting innovators worldwide to design and test new wheel and tire concepts for the MicroChariot Rover. This initiative aims to develop flexible, lightweight, and durable wheels capable of withstanding the Moon’s harsh environment while supporting sustainable surface operations and carrying payloads across rugged terrain. The challenge will unfold in three phases: ideation and design starting this fall, prototyping from winter to spring 2026, and a demonstration phase in summer 2026, with up to $150,000 in prizes available. NASA seeks wheel designs that improve upon rigid wheels by offering higher-speed mobility through better shock absorption, low mass, and extended service life. Participants must demonstrate how their designs can be scaled without re-tooling and explain the underlying science. Finalist prototypes will be tested on NASA’s 100-pound MicroChariot Ground Test Unit, capable of speeds up to 15 MPH. The challenge leverages crowdsourcing to
robotlunar-roverNASAwheel-designmaterials-engineeringspace-explorationmobility-technologyUS uses high-precision 3D printing for Gen IV nuclear reactor parts
The United States is pioneering the use of high-precision 3D printing to create polymer forms for concrete components in advanced nuclear reactors, marking a shift away from traditional steel or wood molds. At Kairos Power’s Oak Ridge campus in Tennessee, these 3D-printed molds are being employed for the Janus shielding demonstration, a test precursor to building parts of the Hermes Low-Power Demonstration Reactor. Hermes is notable as the first advanced reactor to receive a construction permit from the US Nuclear Regulatory Commission. The printed forms, each about 10 feet square and stacked three high, are used to cast the reactor’s bioshield—a thick concrete structure designed to absorb radiation and protect workers during operation. This additive manufacturing approach offers a cost-effective and time-efficient alternative to conventional methods, enabling the construction of complex geometries with high structural integrity under the pressure of wet concrete. The project, a collaboration involving Oak Ridge National Laboratory (ORNL), Kairos Power, and the Manufacturing Demonstration Facility (
energynuclear-energy3D-printingadditive-manufacturingadvanced-reactorsconstruction-technologymaterials-engineeringUK nuclear fusion labs to get 3D boost to build tougher reactor parts
The United Kingdom Atomic Energy Authority (UKAEA) has commissioned two advanced 3D printing machines to produce components for future nuclear fusion reactors capable of withstanding extreme conditions such as high heat, intense neutron radiation, and strong magnetic fields. These machines, housed at the new Central Support Facility, include an electron beam powder bed fusion (E-PBF) system from Freemelt designed to fuse tungsten powder into dense, ultra-tough plasma-facing parts, and a selective laser melting (SLM) machine from Nikon SLM Solutions for fabricating complex geometries and material combinations. Both additive manufacturing methods aim to reduce reliance on traditional fabrication techniques like welding, streamlining production and enhancing precision. UKAEA emphasizes that additive manufacturing is critical for producing the thousands or millions of specialized components required for commercial fusion power plants, as it allows for intricate designs in small volumes with improved efficiency and potentially lower costs. The dual capability of electron beam and laser-based 3D printing under one roof is a pioneering step for the
energynuclear-fusion3D-printingadditive-manufacturingtungstenreactor-componentsmaterials-engineeringWater-based battery breakthrough promises safer, cheaper storage
Researchers at the University of Alberta have developed a breakthrough in water-based (aqueous) rechargeable batteries by redesigning the electrode structure, significantly enhancing their performance. Traditionally, aqueous batteries—such as the lead-acid battery—have been limited by low energy density, voltage, and storage capacity, preventing their use in electric vehicles or large-scale renewable energy storage. The new "pressurized organic electrodes" improve chemical reactivity, electrical conductivity, thermal stability, mechanical strength, and adhesion, enabling faster charging, longer lifespan, and higher energy storage that now surpasses most other organic batteries. This advancement positions aqueous batteries as a safer, cheaper alternative to lithium-ion batteries, which, despite their advantages, carry risks like flammability and higher costs. The University of Alberta team has successfully demonstrated the technology in small coin cells and larger prototypes but acknowledges that scaling up remains a challenge. They are currently seeking industry partners to commercialize the technology for industrial energy storage and potentially electric vehicle applications, aiming to provide a safer
energybatteriesaqueous-batteriesenergy-storagematerials-engineeringelectrode-designrenewable-energy-storage3D-printed jet engine hits 13,000 feet in China’s maiden flight test
China has successfully conducted the maiden flight test of its first fully 3D-printed mini turbojet engine, which reached an altitude of 13,000 feet (4,000 meters) in the Inner Mongolia Autonomous Region. This 160-kilogram thrust-class engine was produced using a combination of additive manufacturing and multi-disciplinary topology optimization, allowing for complex, lightweight, and integrated components that traditional casting and forging methods cannot easily achieve. The development represents a significant technical milestone for China’s aerospace sector, potentially reducing its reliance on foreign-sourced engines and addressing longstanding challenges in metallurgy and precision engineering. While additive manufacturing is already established in the aerospace industry globally—with companies like GE Aviation and Pratt & Whitney using 3D-printed parts—China’s achievement lies in producing an entire flight-validated engine through these methods. The lightweight engine is expected to be particularly useful for unmanned aerial vehicles (UAVs). However, transitioning from a prototype to industrial-scale production poses challenges, including advancements in high-temperature
3D-printingadditive-manufacturingaerospace-materialsjet-engine-technologyadvanced-manufacturingmaterials-engineeringaerospace-innovationFinnish firm produces copper blank for waste nuclear fuel repository
Finnish radioactive waste management company Posiva has produced its first copper casting blank for fabricating a final disposal canister intended for the Onkalo spent nuclear fuel repository, the world’s first deep geological repository for spent nuclear fuel. The casting, completed at Luvata’s plant in Pori, weighed over 17 tons initially and will be machined down to about 12 tons before delivery to the cylinder manufacturer. The casting process was overseen by Finland’s Radiation and Nuclear Safety Authority (STUK) and involved quality improvements such as a larger gravity die to increase casting diameter, ensuring high-quality copper blanks essential for subsequent canister production phases. The copper canister, with five-centimeter-thick walls, acts as a corrosion barrier surrounding a cast iron inner structure that holds 12 spent fuel elements. The inner cast iron component provides structural support and fuel placement, while the copper shell and lid are tightly welded to prevent groundwater intrusion, thereby stopping radionuclides from leaking into the environment. After
energynuclear-waste-managementcopper-castingmaterials-engineeringcorrosion-resistanceradioactive-waste-disposaldeep-geological-repository