Freemelt to conduct feasibility study on 3D printing tungsten parts for fusion reactor developer TAE Technologies

Freemelt, a Swedish electron-beam powder bed fusion (EB-PBF) OEM, announced a feasibility study with U.S. fusion energy developer TAE Technologies. The initial phase will involve printing tungsten components under a technical assessment and manufacturing demonstration, with Freemelt using its EB-PBF process to handle tungsten's high melting point and thermal stresses. If results meet qualification thresholds, the project may advance to further development stages targeting commercial fusion reactor applications. Freemelt CEO Daniel Gidlund framed the collaboration as a strategic move to expand the company's position in the fusion energy sector and demonstrate its expertise in tungsten processing.

This study addresses a well-known materials challenge in the fusion vertical: tungsten's brittleness and crack sensitivity during processing makes it a high-risk material for AM, especially for internal cooling channels and complex geometries that fusion vessel components require. EB-PBF offers vacuum processing and precise energy control that can mitigate these risks compared to laser-based methods. The partnership sits at the intersection of two emerging frontiers - fusion energy, which remains in research-to-commercial transition, and tungsten additive manufacturing, which is still a niche capability with few validated reference parts. Freemelt is positioning against other EB-PBF players like JEOL and Arcam (GE Additive) but with a narrower focus on high-temperature, refractory materials for energy applications.

For this to move beyond feasibility, Freemelt must demonstrate not only geometric success but also repeatable material density, mechanical properties, and radiation resistance across multiple build cycles. TAE, still pre-commercial, needs components that survive extreme thermomechanical loads. The study will be a real test of whether EB-PBF can deliver production-ready tungsten parts, not just prototypes. The AM industry should watch for published property data and any follow-on development contracts as the signal of genuine traction in this hard-to-qualify segment.