Efficient Additive Manufacturing for Advanced U-X Nuclear Fuel Alloys
Closed Special Notice Posted
- Solicitation number
- BA-894
- Agency
-
Department of Energy
- Responses due
- Set-aside
- No set-aside
Opportunity facts
- NAICS code
- 221113 Nuclear Electric Power Generation
- PSC
- 4470 Nuclear Reactors
- Place of performance
- Idaho Falls, Idaho 83415, United States
- Points of contact
-
- Andrew Rankin td@inl.gov
Notice details come from SAM.gov. Updated .
About this opportunity
The Department of Energy has issued a Special Notice highlighting an innovative additive manufacturing technology for nuclear fuel alloy production. This patented technology, developed by Idaho National Laboratory (INL), focuses on using Laser Engineered Net Shaping (LENS) to directly fabricate advanced uranium-based alloys and compounds. The process aims to revolutionize nuclear fuel manufacturing by addressing current inefficiencies in traditional production methods. Specifically, the technology targets complex fuel fabrication challenges by eliminating multiple processing steps and reducing safety risks associated with conventional uranium metal handling. The Special Notice is categorized under Nuclear Electric Power Generation and Nuclear Reactors, indicating its strategic importance in advanced nuclear technology development.
The primary objective of this technology is to streamline nuclear fuel production through a more efficient, cost-effective, and safer additive manufacturing approach. While no specific set-aside or procurement mechanism is detailed, the notice indicates INL's Technology Deployment department is seeking industry partners interested in licensing the intellectual property for commercial development. The technology offers potential applications across commercial nuclear reactors, research reactors, and defense/space exploration sectors, with key advantages including reduced manufacturing complexity, lower material costs, enhanced safety, and improved thermal conductivity. Eligible contractors would likely be companies with capabilities in nuclear technology, advanced manufacturing, or fuel production interested in developing next-generation nuclear fuel solutions. The opportunity remains open until January 13, 2026, providing ample time for potential partners to evaluate and engage with the technology's licensing potential.
Notice text
Efficient Additive Manufacturing for Advanced U-X Nuclear Fuel Alloys
Revolutionizing nuclear fuel production with a streamlined, cost-effective additive manufacturing process for U-X alloys.
The Challenge
Fabricating U-X compounds like U3Si2 and U-Mo alloys for nuclear applications is plagued by inefficiencies and high costs. Traditional methods require multiple processing steps, such as powder fabrication, pressing, and sintering, all of which introduce production delays and increased safety concerns. Moreover, the reliance on uranium metal and conventional techniques creates additional hazards and regulatory challenges, impeding commercial scalability and adoption.
How It Works
This patented technology employs a Laser Engineered Net Shaping (LENS) additive manufacturing process to directly fabricate U-X alloys and compounds:
- Precision Deposition: The LENS system uses a localized melt pool to blend multiple powder sources, ensuring uniform chemical composition and properties.
- Versatility: The method accommodates gas/solid and solid/solid reactions, enabling the production of various fuel types, including monolithic and dispersive metallic fuels.
- Minimized Variability: Controlled deposition minimizes absorptance fluctuations, ensuring consistency in material properties.
- Simplified Workflow: This eliminates intermediate steps such as powder preparation and pressing, directly converting uranium precursors like UF4 into finished fuel forms.
Key Advantages
- Reduced Complexity: Eliminates multiple traditional steps, streamlining the manufacturing process.
- Lower Costs: Avoids the need for uranium metal, reducing material costs and associated security requirements.
- Enhanced Safety: Minimizes hazards by replacing traditional powder metallurgy with additive techniques.
- Improved Thermal Conductivity: Facilitates the production of accident-tolerant fuels like U3Si2, with superior thermal performance compared to UO2.
- Customizable Fuel Designs: Enables precise control over alloy composition, supporting tailored solutions for diverse reactor needs.
Market Applications
- Commercial Nuclear Reactors: Fabrication of U3Si2 as a next-generation accident-tolerant fuel for light water reactors.
- Research Reactors: Production of low-enriched uranium fuels, such as U-Mo monolithic and Al-matrix dispersive fuels, essential for scientific research and isotope production.
- Defense and Space Applications: Advanced nuclear fuels for specialized reactors in defense and space exploration.
INL’s Technology Deployment department focuses solely on licensing intellectual property and collaborating with industry partners who can commercialize our innovations.
We do not engage in purchasing, procurement, or hiring external services for technology development. Our objective is to connect with companies interested in licensing and bringing our technologies to market.
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