Freemelt

Freemelt has been collaborating with UKAEA since April 2023 and is currently delivering large-scale production tests of 3D printed tungsten tiles for fusion machines, as part of an ongoing proof-of-concept. UKAEA is now advancing 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. 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.

“UKAEA's investment in eMELT is an important confirmation that our E-PBF (Electron Beam Powder Bed Fusion) technology meets the demanding requirements in fusion, further strengthening our position in the energy sector,” says Daniel Gidlund, CEO of Freemelt.

Fusion has the potential to revolutionize 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.

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 USD 300 billion in 2023 to USD 500 billion by 2030, corresponding to an annual growth rate of 7.4%. In the fusion sector, investments reached USD 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), strengthening 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 1.5 million tungsten tiles, while smaller machines under development by private fusion companies will require about 10 percent of ITER’s volume.

UKAEA is a leading player in fusion energy research and development, driving several advanced research projects to commercialize 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.