NN Asks: What’s the biggest challenge in scaling fuel fabrication?

September 30, 2025, 7:06AMNuclear NewsJennifer Wheeler

Jennifer Wheeler

In this new era of nuclear, the word “scalable” can mean many different things. From new advanced reactor designs that can meet the diverse needs of big power users like hyperscalers to industrial process heat applications, and from remote rural communities to new fuel cycle facilities (conversion, enrichment, deconversion, fuel fabrication), there is much to consider when predicting and meeting developing demand signals.

The biggest challenge in scaling fuel fabrication is recognizing that scaling applies to much more than taking the specific process equipment used to manufacture fuel products from pilot scale to commercial scale to nth-of-a-kind scale. For a first-of-a-kind fuel facility where there is no available reference facility to use as a basis, there is a delicate balance—and often an iterative dance—between fuel demand, right-sizing the facility, and project financing. Let’s focus on three major areas: factory throughput, staffing, and space.

Factory throughput depends on balancing a predicted fuel demand quantity and timing with process equipment cycle time, unit throughput, and management of bottleneck steps in the overall process flow. Ideally, there would be time and space to set up commercial-scale equipment for testing to gather real-time processing data. Use of equipment modules for each manufacturing step enables factory throughput to be scaled as a function of unit throughput by using test data and process simulation models to estimate the number of machines required per manufacturing step. Then the storage capacity and frequency of deliveries for raw input materials and finished products awaiting shipment can be determined.

Staffing for operation of the process equipment can be derived using process simulation models and test data for the time it takes to load/unload a machine, process equipment cycle time and up-time assumptions, and factory throughput. Staffing for maintenance and technical support functions is more challenging to scale directly to unit/factory throughput.

You can never have too much space . . . except when you’re paying to build it. The number of machines per manufacturing step drives the physical size of the process cell or room, including additional space to load/unload machines and access for routine maintenance. Support spaces can be easy to define but harder to size when there is no comparable operation—maintenance/calibration, shipping and receiving, waste accumulation and packaging, and spare parts storage are good examples. Planning ahead for initial equipment installation as well as future equipment replacements is important when machine sizes are larger than pedestrian-sized doors.

These are only a few examples of the kind of multivariable, iterative decision-making needed to bring a FOAK fuel fabrication facility into reality. For me, it’s an engineering nerd’s dream project—so many problems to solve!


Jennifer Wheeler (jwheeler@triso-x.com) is vice president of regulatory affairs at TRISO-X LLC.