Freemelt extends UKAEA partnership with tungsten tiles production scalability
February 10, 2025
Freemelt AB, based in Mölndal, Sweden, has received an order from the UKAEA (United Kingdom Atomic Energy Authority) to conduct production scalability tests of additively manufactured tungsten tiles for fusion energy power plants. The order is expected to be delivered during the first quarter of 2025.
This project is a continuation of previous feasibility studies performed by the two organisations. The proof-of-concept project target is to demonstrate volume production using Electron Beam Powder Bed Fusion (PBF-EB) and, in particular, Freemelt’s eMelt machine .
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Freemelt and UKAEA, which have been collaborating since April 2023, have carried out two feasibility studies: the first focused on process development and the second, application testing. In this project, Freemelt intends to demonstrate production scalability of tungsten tiles, a critical step in validating the potential for future volume production. As part of this study, the repeatability of the PBF-EB process will be evaluated to support component qualification programmes for potential use in next-generation fusion energy power plants.
Fusion energy has great potential as energy source, and during the coming years, large experimental tokamaks (experimental fusion reactors using fusion energy) and fusion power plants will require significant volumes of advanced components.
“The fact that we now advance the collaboration to volume production tests of tungsten tiles is an important confirmation that our E-PBF technology meets the demanding requirements in fusion energy,” stated Daniel Gidlund, Freemelt CEO. “Tungsten is one of the most challenging materials to process, and our technology enables the production of complex components with high quality. This is an opportunity to further strengthen our position in the energy sector.”
Unlike today’s nuclear power which relies on fission (nuclear splitting), fusion does not produce long-lived radioactive waste. However, for the process to succeed, extremely high temperatures and advanced materials that can withstand the harsh conditions of the fusion environment are essential.
Test fusion machines like experimental tokamaks are essential for validating fusion technology before scaling to commercial electricity production. They require millions of tungsten components. ITER, the world’s largest experimental tokamak, is predicted to need between 1-1.5 million tungsten tiles, while smaller power plants under development by Tokamak Energy will require about 10% of ITER’s volume.
UKAEA is the UK’s national organisation responsible for fusion energy development and commercialisation, driving several advanced research projects to commercialise fusion as a safe, sustainable, and emissions-free energy source. Through collaborations with industry and academia, UKAEA aims to drive the development of new materials and manufacturing methods required for future fusion power plants.
