The United Kingdom Atomic Energy Authority (UKAEA) has made a significant effort toward developing operational fusion reactors. It has placed an order for Freemelt’s eMELT machine, and the investment is valued at approximately $800,000.
“Fusion has great potential as an energy source, and in the coming years, prototype fusion machines and power plants will require significant volumes of advanced components,” said Freemelt in a press release.
This investment will enable UKAEA to advance its in-house development and production of critical fusion components. The investment is particularly aimed at tungsten tiles designed to withstand the extreme temperatures within fusion reactors.
“Prototype fusion power plants and machines are essential for validating fusion technology before scaling to commercial electricity production, requiring millions of tungsten components,” added Freemelt.
Sweden-based Freemelt, a developer of industrial metal additive manufacturing (AM) solutions, is providing its eMELT system, which utilizes Electron Beam Powder Bed Fusion (E-PBF) technology.
This technology offers high efficiency and is crucial for producing the high-performance materials needed for fusion energy applications. eMELT is one of Freemelt’s modular 3D printers, which is designed for industrial applications and supports complex geometries.
“The eMELT state-of-the-art electron gun combines high power with consistent beam quality, a critical component for maximizing productivity and achieving exceptional quality without compromise,” noted Freemelt.
Notably, the collaboration between Freemelt and UKAEA began in April 2023, and it has focused on large-scale production tests of 3D-printed tungsten tiles.
Tungsten is a key material due to its high melting point and ability to withstand the intense heat generated in fusion reactions. UKAEA’s acquisition of the eMELT system marks a transition from proof-of-concept to in-house production.
“UKAEA’s investment in eMELT is an important confirmation that our E-PBF (Electron Beam Powder Bed Fusion) technology meets the demanding requirements in fusion, further strengthening our position in the energy sector,” said Daniel Gidlund, CEO of Freemelt.
Fusion energy promises clean and sustainable power
“Unlike today’s nuclear power, which relies on fission (nuclear splitting), fusion does not produce long-lived radioactive waste,” highlighted the press release.
However, fusion relies on achieving extremely high temperatures. This necessitates advanced materials capable of enduring the harsh conditions within fusion reactors.
Subsequently, the demand for these materials is expected to surge as prototype fusion machines and power plants are developed.
Fusion sector’s rise drives tungsten demand
“In the fusion sector, investments reached USD 7.1 billion in 2024, driven by large-scale research projects and increased private investments,” highlighted the press release.
Major research projects like STEP (UK), ITER, and DEMO, as well as increased private funding from companies like Commonwealth Fusion Systems, have played a major role in this rapid emergence of the fusion sector.
Therefore, the demand for fusion reactor materials, like tungsten, is extremely high. For reference, ITER, the world’s largest fusion reactor, alone is projected to require between 1 and 1.5 million tungsten tiles. Smaller private fusion machines will also need significant volumes of these components.
UKAEA’s investment in Freemelt’s eMELT technology underscores the critical role of advanced manufacturing in making fusion energy a reality.
“Fusion has great potential as an energy source, and in the coming years, prototype fusion machines and power plants will require significant volumes of advanced components,” concluded the press release.
