UK Atomic Energy Authority orders Freemelt eMELT machine to develop fusion components
March 27, 2025
Freemelt AB, based in Mölndal, Sweden, has received an order for its eMelt Electron Beam Powder Bed Fusion (PBF-EB) Additive Manufacturing machine from the United Kingdom Atomic Energy Authority (UKAEA).
Freemelt has been collaborating with UKAEA since April 2023 and is currently delivering large-scale production tests of additively manufactured tungsten tiles for fusion machines, as part of an ongoing proof-of-concept. UKAEA is now working to advance to in-house development and production of fusion components through an investment in Freemelt’s industrial machine eMELT, which supports both feasibility studies and proof-of-concept.
“UKAEA’s investment in eMELT is an important confirmation that our [PBF-EB] technology meets the demanding requirements in fusion, further strengthening our position in the energy sector,” Daniel Gidlund, CEO of Freemelt, shared.
Fusion has great potential as an energy source, and in the coming years, prototype fusion machines and power plants will require significant volumes of advanced components. 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.
Recent advancements in fusion, both internationally and through Swedish companies like Novatron, have increased interest in the technology. Total investment in the energy sector is expected to rise from $300 billion in 2023 to $500 billion by 2030, corresponding to an annual growth rate of 7.4%. In the fusion sector, investments reached $7.1 billion in 2024, driven by large-scale research projects and increased private investments from companies such as Commonwealth Fusion Systems. Additionally, substantial public funding has supported major research initiatives such as STEP – the UK’s prototype fusion power plants – as well as ITER and DEMO (Demonstration Fusion Power Reactor), in an effort to strengthen fusion as a key strategic energy technology.
Prototype fusion power plants and machines are essential for validating fusion technology before scaling to commercial electricity production, requiring millions of tungsten components. ITER, the world’s largest fusion reactor, is predicted to need between 1 and 15 million tungsten tiles, while smaller machines under development by private fusion companies will require about 10% of ITER’s volume.
UKAEA acts as a key player in fusion energy research and development, driving several advanced research projects to commercialise fusion as a safe, sustainable, and emission-free energy source. Through collaborations with industry and academia, UKAEA is driving the development of new materials and manufacturing methods required for future fusion power plants.
