Digital engineering, which uses advanced technologies to capture data and optimize design in a digital environment, is being applied for the first time to a DOE nuclear project and has already realized substantial benefits.
With a new generation of nuclear reactors in the works, Idaho National Laboratory has embraced digital engineering (DE) as a means of achieving the same efficiencies that companies in the private sector have been able to realize in everything from concert halls to aircraft engines.
DE—using advanced technologies to capture data and craft design in a digitized environment—has been evolving since the 1990s. For Mortenson Construction, a worldwide construction firm, using virtual design and construction resulted in a cumulative 600 days saved over 416 projects and a 25 percent increase in productivity. By building digital twins for assets, systems, and processes, DE has avoided more than $1.05 billion in customer, production, and mechanical losses.
Leaders at INL recognized in 2018 that DE could be useful in the design and construction of new commercial and test reactors. Managing construction costs, timing, and performance will be essential to maintain U.S. competitiveness.
The DOE’s Transformational Challenge Reactor program is harnessing recent advances in manufacturing, materials, and computational sciences to rapidly build and operate an advanced reactor core.

The TCR program is leveraging an agile approach—one that is centered around continuously informing the process—to accelerate deployment timelines and introduce performance improvements. Image: Adam Malin, ORNL
Soon after Enrico Fermi’s Chicago Pile-1 went critical for a brief duration in December 1942, the construction of the first continuously operating reactor, the X-10 Graphite Reactor, was initiated in February 1943 at Clinton Engineer Works in Oak Ridge, Tenn. On November 4 of that year, a mere nine months after the start of construction, the reactor began operation. This marked the onset of what Alvin M. Weinberg referred to as “the first nuclear era,” during which many reactors of various designs and operating parameters were built and demonstrated across the United States. Forty years ago, the Fast Flux Test Facility was the last U.S. non-light-water reactor to reach criticality, and it has since been decommissioned.