---
title: "3D printing powers fusion progress at Princeton"
url: https://www.voxelmatters.com/3d-printing-powers-fusion-progress-at-princeton/
date: 2025-06-01
modified: 2025-06-01
lang: en
author: "Edward Wakefield"
description: "According to the Princeton Plasma Physics Laboratory (PPPL), 3D printing is playing a pivotal role in advancing fusion energy research by streamlining assembly and reducing risk in the upgrade of..."
categories:
  - "AM for Energy"
  - "Rapid Prototyping"
  - "Research & Education"
tags:
  - "insights"
image: https://www.voxelmatters.com/wp-content/uploads/2025/06/20250528_3d_print_photos_5k6a9427_ks2-640x360.jpeg
word_count: 412
---

# 3D printing powers fusion progress at Princeton

[According to the Princeton Plasma Physics Laboratory (PPPL)](https://www.pppl.gov/news/2025/3d-printed-part-worthy-hollywood-set-stands-nstx%E2%80%91u%E2%80%99s-central-magnet), 3D printing is playing a pivotal role in advancing fusion energy research by streamlining assembly and reducing risk in the upgrade of the National Spherical Torus Experiment (NSTX-U). Engineers are using [full-scale 3D printed models](https://www.voxelmatters.com/norsk-titanium-completes-full-scale-article-testing-with-ga-asi/) to simulate complex assembly steps, verify component fit, and avoid costly delays before the real parts arrive.

The core of NSTX-U is a powerful magnet bundle made up of a toroidal field (TF) magnet and an ohmic heating (OH) coil. The TF magnet will carry up to 4 million amps to confine superheated plasma, while the OH coil generates the electric field that heats it. This system is essential to testing whether compact spherical tokamaks can offer a more efficient path to fusion power.

![3D printing powers fusion progress at Princeton - streamlining assembly and cutting risks for PPPL’s spherical tokamak experiment.](https://www.voxelmatters.com/wp-content/uploads/2025/06/NSTX-U-May-Update_3D-printed-parts.jpeg)3D printed components on NSTX-U. Credit: NSTX-U project team / PPPL.
While the actual TF-OH bundle is being built at Elytt Energy in Spain, the PPPL team produced a 40-inch-tall, 3D printed replica to act as a stand-in. “[If it were a Hollywood set](https://www.voxelmatters.com/3d-printing-bombshell-charlize-theron/) and you painted the TF-OH 3D print a different color, it would look just like the machine,” said Tom Jernigan, Senior Project Manager.

This prototype allows engineers to pre-fit 36 cooling water lines and other components in advance. “The use of [3D printed prototypes](https://www.voxelmatters.com/twingo-e-tech-prototype-features-3d-printed-bumpers/) has been instrumental toward reducing risk and accelerating the schedule,” said Dave Micheletti, Project Director at NSTX-U. “It allows us to positively confirm that components will fit together and eliminates the risk of rework once final assembly starts.”

![3D printing powers fusion progress at Princeton - streamlining assembly and cutting risks for PPPL’s spherical tokamak experiment.](https://www.voxelmatters.com/wp-content/uploads/2025/06/NSTX-U-May-Update_TF-Compaction.jpeg)The four quadrants of the toroidal field coil are compacted at Elytt Energy. Credit: NSTX-U project team / PPPL.
To date, the team has fabricated [more than 50 3D printed components](https://www.voxelmatters.com/atang-tshikare-installs-3m-long-3d-printed-sculpture-at-time-out-market-in-south-africa/), including copper bus bar models and precision brackets. These have been used to confirm alignment before real parts are produced and installed. They also pre-fitted 2,000 plasma-facing tiles within extremely tight tolerances—an essential step for withstanding the intense heat of fusion.

At Elytt Energy, 3D printed prototypes have guided the manufacturing of the TF magnet, which is being built in four compacted quadrants. These will be wrapped with the OH coil and sealed into one solid magnet through vacuum pressure impregnation.

When the final TF-OH bundle returns to PPPL in late 2025, it will be inserted into the NSTX-U vacuum vessel, ready to bring this next-generation fusion experiment to life—with 3D printing quietly behind the scenes, making it all fit.