UK-based engineering equipment supplier Kingsbury and metal additive manufacturing company Additure have been appointed by the UK Atomic Energy Authority (UKAEA) to supply additive manufacturing technology and expertise as part of the UK’s ongoing efforts to advance fusion energy research. The partnership will support the development of components designed to endure the extreme conditions within fusion reactors, with a focus on innovative materials and design approaches.
A key area of focus involves the use of tungsten—layered with materials such as copper—to achieve the necessary durability. To support this work, Kingsbury and Additure will deliver and install a Nikon SLM Solutions SLM 280 2.0 Laser Powder Bed Fusion (LPBF) system at UKAEA’s facilities.
“We are excited to support the team at the UKAEA as they scale, not just with the SLM 280’s LPBF capability, but with all the key elements of the AM ecosystem to make this a robust manufacturing solution for UKAEA and the UK’s fusion programme,” said Will Priest, Business Development Manager at Additure.
About UKAEA
The UK Atomic Energy Authority (UKAEA) is the United Kingdom’s national fusion energy research organisation. It operates as an executive non-departmental public body, sponsored by the Department for Energy Security and Net Zero. A key part of its mission involves fostering industrial fusion capability by working with manufacturers and supply chains to introduce and scale the technologies required for commercial fusion energy deployment.
“The UKAEA aims to develop the commercialisation of additive manufacturing and support UK industry in the transition into the fusion energy sector. We conduct the complex areas of research and development to the point where it becomes commercially viable, the advice and support of our supply chain is hugely valuable in expediting this process,” said Roy Marshall, Head of Operations for Fabrication, Installation, and Maintenance at UKAEA.
Additure’s Role and Technology Contribution
At the center of this initiative is the SLM 280 2.0, an LPBF system designed for high-performance applications, including the development of refractory metals. The system offers build speeds up to 80% faster than single-laser alternatives and includes integrated safety features such as a powder sieve module and system cooling enhancements.
Beyond equipment delivery, Additure is also providing comprehensive technical training to UKAEA’s research, materials, and design teams. This includes detailed guidance on machine setup, build optimization, and specialized functions—such as a heated reduced build volume.
“The applications training from Additure will provide our engineers with new ways to design some of the complex structures required by fusion and allow them to do this using some of the most challenging materials to work with. For additive manufacture to contribute to fusion energy, more designers need to think, ‘What process is most suitable for the desired thermal or structural performance?’ And ‘how do I create a design that is best optimised for additive manufacture?’”, said Mr. Marshall.
Advancing Laser Beam Shaping 3D Printing
Given its notable advantages for industrial metal 3D printing, beam shaping capabilities are being developed and commercialized by several players in the research and LPBF 3D printing spheres. In 2024, German research organization Fraunhofer Institute for Laser Technology ILT showcased its new 3D printing beam shaping technology. Working with the Chair of Technology of Optical Systems (TOS) at RWTH Aachen University, the new platform, the Fraunhofer team is developing a test system for investigating complex laser beam profiles.
This platform can create customized beam profiles for laser powder bed fusion (LPBF) 3D printing, enhancing part quality, process stability and productivity, while minimizing material waste.
In 2022, Equispheres and Aconity3D used laser beam-shaping 3D printing to achieve build rates nearly nine times higher than industry norms. Equispheres’ NExP-1 aluminum powder was used with Aconity3D’s AconityMIDI+ LPBF 3D printer to unlock speeds exceeding 430 cm3/hr for a single laser.
The system was modified to employ a PG YLR 3000/1000-AM laser with beam-shaping capabilities. By using a shaped beam over a zoomed Gaussian profile, the team reduced overheating and mitigated spatter formation during high-speed 3D printing.
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Featured image shows JET interior with super imposed plasma. Image via UK Atomic Energy Authority.
