---
title: "ORNL uses 3D printing to fabricate canisters for PM-HIP of large metal components"
url: https://www.voxelmatters.com/ornl-uses-3d-printing-to-fabricate-canisters-for-pm-hip-of-large-metal-components/
date: 2026-05-15
modified: 2026-05-15
lang: en
author: "Joseph Caron-Dawe"
description: "Researchers at the US Department of Energy's Oak Ridge National Laboratory (ORNL) have developed a method for using additive manufacturing to produce custom canisters for powder metallurgy hot isostatic pressing..."
categories:
  - "3D Printing Processes"
  - "AM for Energy"
  - "Metal Additive Manufacturing"
  - "Nuclear Energy"
tags:
  - "future"
image: https://www.voxelmatters.com/wp-content/uploads/2026/05/ORNL-3D-printed-PM-HIP-01-640x400.jpg
word_count: 388
---

# ORNL uses 3D printing to fabricate canisters for PM-HIP of large metal components

[Researchers at the US Department of Energy's Oak Ridge National Laboratory (ORNL)](https://www.voxelmatters.directory/company/oak-ridge-national-laboratory/) have developed a method for using additive manufacturing to produce custom canisters for powder metallurgy hot isostatic pressing (PM-HIP).

Canisters made via PM-HIP, in which metal powder is consolidated into fully dense structural parts such as turbine components and pressure vessels, are usually produced through metal forming, machining and welding, but this multi-step sequence can introduce defects, raise costs and constrain design flexibility.

[The ORNL team](https://www.voxelmatters.com/ornl-wins-2026-sme-award-for-3d-printed-precision-nuclear-reactor-molds/) replaced that sequence with 3D printing, which meant complex canister geometries were instead tailored to the final part geometry. The approach also reduces material waste and shortens production time by bringing parts closer to their finished shape before processing begins. 

Several AM methods were used by the ORNL team, including laser- and wire-based techniques. According to the team, the use of AM in fabricating HIP canisters had not previously been explored.

Once printed, the canister is filled with metal powder, vacuum-sealed and placed in a hot isostatic press, where heat and pressure consolidate the powder into a solid component with minimal internal defects.

“This work lays the foundation for a transformative shift in the PM-HIP landscape for large-scale components,” stated Pavan Ajjarapu, researcher at ORNL. “By harnessing the strengths of both additive manufacturing and hot isostatic pressing, we are paving the way for greater design freedom and expanded applications in hydropower and next-generation nuclear reactors.”

[![ORNL uses 3D printing to fabricate canisters for PM-HIP of large metal components](https://www.voxelmatters.com/wp-content/uploads/2026/05/ORNL-3D-printed-PM-HIP-02-640x400.jpg)](https://www.voxelmatters.com/wp-content/uploads/2026/05/ORNL-3D-printed-PM-HIP-02.jpg)

## Supply chain and computational advantages

The method also carries implications for domestic manufacturing capacity. “This approach offers an alternative to casting and forging,” said ORNL's Soumya Nag. “It could also help strengthen US manufacturing and national security by easing supply chain shortages.”

In parallel, researcher Subrato Sarkar developed custom simulations to predict how parts may [distort or change shape under heat and pressure during processing](https://www.voxelmatters.com/vcsel-heating-reduce-thermal-stress/). “A deeper understanding of how the PM-HIP process works can help eliminate uncertainties related to these predictions,” Sarkar stated.

ORNL's Jason Mayeur described an additional computational layer: “We further enhanced the effectiveness of PM-HIP technology by using a mechanics-based computational model to reduce developmental costs and lead times by eliminating trial-and-error approaches.”

The research builds on a 2024 project at ORNL's Manufacturing Demonstration Facility (MDF) in which researchers produced a 2,000-pound hydropower impeller canister prototype from initial design to finished part in just two days.