Quicker and cheaper: Kairos Power intends to use 3D-printed forms at a larger scale for its future commercial plants. According to the company, the forms cut down production timelines, enabling “cast-in-place” construction of structural components with unique geometries “in days rather than weeks,” according to an ORNL news release. The DOE added that compared to traditional methods relying on steel or wood forms that can be costly, imprecise, and time-consuming to build, this shift marks a significant advancement in nuclear construction methodology.
“We’re taking the best of additive manufacturing—modularity, flexibility, rapid iteration—and applying it to nuclear energy,” said ORNL’s Ahmed (Arabi) Hassen, group leader for composites innovation. “This project shows that we can break through old methods with new technologies that lower barriers, reduce risk, and accelerate construction timelines.”
The forms for the shielding demonstration needed to withstand the pressure exerted by the heavy concrete they were designed to shape. Hassen said that a challenge has been to maintain the structural integrity of the forms under high stress, which requires mechanical resilience, innovative design, and printing strategies.
Collaborators: The MDF, supported by the DOE’s Advanced Materials and Manufacturing Technologies Office, is a nationwide consortium of collaborators working with ORNL to help transform U.S. manufacturing. The Kairos Power site demonstration project was also supported by multiple industry partners, including Airtech, TruDesign, Additive Engineering Solutions, and Haddy, which collectively established a new supply chain for nuclear infrastructure enabled by additive manufacturing.
Moonshot: The collaboration with Kairos Power was enabled by a multiyear initiative called the SM2ART Moonshot Project, led by the MDF and the University of Maine and funded by the DOE’s Advanced Materials and Manufacturing Technologies Office. The project uses ORNL’s materials science expertise, supercomputing and artificial intelligence resources, and large-format additive manufacturing capabilities, while the University of Maine’s focus is on large-scale 3D printing, structural infrastructure development, and digital manufacturing platforms.
Over the next 18 months, the SM2ART Moonshot Project will continue to support Kairos Power construction, expanding to include full-scale production of forms for radiation shielding and reactor building enclosures and integrating smart manufacturing techniques, digital twins, and data-driven quality control. The partners aim to use printable biocomposite feedstocks derived from timber residuals, targeting a 75 percent reduction in material cost using domestic forest products.
By demonstrating that nuclear construction can adopt manufacturing practices, from design agility to rapid deployment, the project offers a compelling vision for lowering the cost and timeline of future reactors.
Quotes: “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. “We’re combining national lab capabilities with MDF’s legacy of taking big, ambitious swings—moonshots that turn bold ideas into practical solutions—to accelerate new commercial nuclear energy.”
Barnard Construction played a key role, implementing and adapting the 3D-printed formwork, providing real-time feedback, and incorporating design changes on the fly to enhance constructability and enable rapid deployment. Dehoff said that the project’s success stemmed from communication between the partners. “It’s a real example of national lab innovation in action,” he said.
Edward Blandford, cofounder and chief technology officer of Kairos Power, noted that the MDF moves fast, thinks creatively, and has demonstrated that transformative results can be delivered when conventional manufacturing falls short. He explained that while exploring options for precast concrete systems, Kairos Power received a recommendation from a commercial partner to talk with the MDF. “It’s not often we get advice from industry to call the national lab because they move quickly,” he said.
Blandford added, “This project fits squarely into our iterative development approach. By building and testing the molds for the columns first, we’re able to refine our methods, engage early with regulators, and reduce risk before we scale up the construction method for Hermes and future plants. That’s been a core part of our strategy from day one.”
