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Gap analysis survey – SMRs and 3D printing

Guidelines for Implementing Advanced Manufacturing Technologies in the Canadian Nuclear Industry

Introduction

In 2023, National Resources Canada (NRCan) introduced the Enabling Small Reactors Program with the objectives to support the development of supply chains for small modular reactor (SMR) manufacturing and SMR fuel supply and to fund research on SMR waste management solutions. Canadian Nuclear Laboratories (CNL), in collaboration with InnoTech Alberta, received funding under the program for the project entitled “Guidelines for Implementing Advanced Manufacturing Technologies in the Canadian Nuclear Industry”.

The purpose of this project is to develop a guideline for using advanced manufacturing techniques within the Canadian nuclear framework of codes and standards. A scaled version of a SMR component will be fabricated using advanced manufacturing technologies and a range of inspections and tests will be performed on the manufactured components to evaluate their properties.

The project brings together SMR vendors, equipment suppliers, advanced manufacturing experts, and regulatory bodies to successfully navigate the engineering, quality, and regulatory challenges related to the implementation of these developing technologies in a uniquely constrained environment.

As part of this fully funded project, the following survey was created to help identify areas, systems, or specific components that have been identified as areas where there currently exist gaps in the supply chain. Participation to the survey is voluntary. The results of the survey will be used to generate a shortlist of systems and components and select a final component that will be fabricated by additive manufacturing.

Additive Manufacturing

Additive manufacturing (AM), commonly known as 3D printing, is a manufacturing process that creates objects by adding material layer by layer based on a digital design, as opposed to subtractive manufacturing and formative manufacturing technologies. The AM technology has been adopted in various industries, including aerospace, automotive, healthcare, and consumer goods by offering advantages like rapid prototyping, customization, reduced waste, and lower production costs.

Additively manufactured components have shown significant potential in the nuclear industry, offering innovative solutions to many of the challenges faced by the sector. The use of 3D printing technology in nuclear applications provides advantages in areas such as design flexibility, cost efficiency, rapid prototyping, and parts consolidation. Additively manufactured components have recently been installed in nuclear reactors. Examples include anti-debris filters installed at the base of fuel assemblies and upper tie plate grids installed at the top fuel assemblies.

Gap analysis survey - SMR/3D printing

Section 1: General Information

1. What is your role or position in the nuclear industry?
2. Which type of Small Modular Reactor (SMR) is being considered/designed?
3. Are there components, parts, or systems that don’t have technologies identified for their manufacturing or fabrication?
4. What are the main functions of these component(s) identified in Question 3 in the SMR system?
5. Have the relevant codes and standards associated with this component in the SMR system been identified?
6. Are you willing to share intellectual property information with a research group for non-commercial purposes?

Section 2: Material and Manufacturing Technology

7. What materials are the components made from?
8. Were the components designed to withstand specific operating conditions of the SMR, such as high radiation levels, elevated temperatures, or thermal cycling?
9. What are the scales or approximate dimensions of the components?

Section 3: Performance and Functionality

10. Have the components been tested in relevant conditions for SMRs (e.g., heat, pressure, temperature, radiation)?
11. What is the expected lifespan of the components in the SMR system?

Section 4: Safety, Regulatory, and Compliance

12. Have the components been assessed for potential risks related to radiation exposure, thermal stress, and material degradation in SMR conditions?
13. Are there any concerns regarding the use of 3D-printed components in SMRs from a safety perspective?
14. Are there gaps in the codes and standards that hinder the use and adoption of 3D-printed components in SMRs?

Section 5: Design, Integration, and Future Prospects

15. How compatible are 3D-printed components with existing SMR designs and integration requirements?
16. What benefits do you see in using 3D-printed components for SMRs compared to traditional manufacturing methods?
17. What challenges do you foresee in scaling up the use of 3D printing for SMR components?

Section 6: Future Use and Improvements

18. Do you believe that 3D printing will play a significant role in the future of SMR design and manufacturing?
19. Are you currently using 3D printing in other parts of your business?
20. What improvements would you recommend for 3D-printed components in SMRs?
21. Are you interested in providing guidance or partnering on research and development work with CNL on additive manufacturing for nuclear reactor components?
22. May the project team contact you to discuss your responses in further details?

Thank you for your participation!

Your insights are invaluable to the ongoing development and adoption of 3D-printed parts in SMRs. We appreciate your time and expertise.

Contact

Eric Sansoucy
eric.sansoucy@cnl.ca