LFAM enables the future of nuclear energy at ORNL
Using 3D printed polymer composite molds to shape concrete, in partnership Kairos Power
In a major advancement for nuclear construction, the Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL), in partnership with Kairos Power and Barnard Construction, has developed and validated large-scale 3D-printed polymer composite forms. These are used to cast complex concrete structures for Kairos Power’s Hermes Low-Power Demonstration Reactor, now under construction at their Oak Ridge campus.
These 10-by-10-foot forms, stacked three high, were displayed at the East Tennessee Economic Council’s Nuclear Opportunities Workshop in July. They serve as precursors for forms to be used in the Hermes reactor, enabling “cast-in-place” construction of intricate geometries in days instead of weeks. Unlike traditional wood or steel forms, these 3D printed molds significantly reduce time and cost.
“At ORNL, we’re showing that the future of nuclear construction doesn’t have to look like the past,” said Ryan Dehoff, Director of the MDF. ORNL’s decade of “moonshots,” from 3D printing cars and homes to real-time digital part qualification, is now modernizing nuclear energy.
Kairos Power co-founder and CTO Edward Blandford highlighted the MDF’s speed and creativity: “They move fast, they think creatively, and they’ve demonstrated that they can deliver transformative results when conventional manufacturing would fall short.” Referred to MDF by a commercial partner, Blandford said, “It’s not often we get advice from industry to call the national lab because they move quickly.”
“This project fits squarely into our iterative development approach,” Blandford added, emphasizing early testing to reduce risk and streamline regulatory engagement.
The Janus column form is part of Kairos Power’s bioshield design – a concrete structure shielding workers from reactor radiation. Partners, including Airtech, TruDesign, Additive Engineering Solutions, and Haddy, established a new additive-enabled supply chain. Barnard adapted the forms, giving real-time feedback and implementing design changes.
ORNL’s Ahmed (Arabi) Hassen explained that the challenge was ensuring the molds maintained structural integrity under high concrete pressure, requiring cutting-edge design and print strategies.
Funded by DOE’s Advanced Materials and Manufacturing Technologies Office, the project is part of the SM2ART Moonshot Project, led by MDF and the University of Maine. It combines advanced materials science, AI, and large-format 3D printing to modernize nuclear construction. Over the next 18 months, the project will scale up to full-size shielding forms using smart manufacturing and low-cost, timber-based biocomposites.
