US startup Ampera has produced what it claims is the first 3D-printed nuclear reactor module. The firm says it is working towards delivering scalable, emission-free power for datacenters, defense applications, and off-grid sites. Ampera unveiled its first nuclear reactor module during an event at the firm's innovation center in Palm Beach Gardens, Florida. More than 100 people attended, including local officials, business leaders and employees. Founder and CEO Brian Matthews revealed the prototype microreactor, which features a fully 3D-printed silicon carbide reactor core and pressure vessel. "This next-generation nuclear core and pressure vessel sets the foundation for factory-built, mass-produced nuclear energy," Matthews said. "The advanced technology and additive manufacturing used demonstrate a clear commercial path for new nuclear technology coming to market in an accelerated manner." His company is developing a subcritical, solid-state, factory-built thorium-based nuclear reactor. Subcritical means the fuel cannot sustain a nuclear chain reaction on its own, which prevents a runaway power excursion. Ampera uses "solid-state" to describe a design with solid rather than liquid fuel. The proposed fuel uses tristructural isotropic, or TRISO, particles, consisting of a fuel kernel containing thorium, surrounded by multiple ceramic and carbon layers. Thorium-232 is not fissile. After absorbing a neutron, it ultimately decays through thorium-233 and protactinium-233 into fissile uranium-233. This requires a separate source of neutrons, and Ampera says its design features a proprietary neutron driver to provide a stable external neutron source to start and sustain operation. In June, Ampera announced it had established an Australian subsidiary to secure thorium supplies, and said it plans to produce the fuel kernels itself. "Thorium is the future for ultra-safe, clean power production," Matthews said at the time. "By producing TRISO thorium kernels in the United States, we can ensure ample access to the needed fuel supply as we scale up and also minimize price volatility risk." Ampera also describes the heart of the reactor as as a spherical monolithic gyroid core. A gyroid, as far as we can fathom, is a complex shape that provides a massive surface area relative to its volume, making it well-suited for heat transfer. Its complexity makes it difficult to produce using conventional manufacturing methods, which is where additive manufacturing comes in. The core is 3D-printed using silicon carbide and designed to operate for up to 30 years without refueling, the firm claims. Ampera says its planned systems will provide 15 or 30 MWe, depending on the configuration, enough to supply a typical datacenter. Larger configurations are planned. Matthews said that his company expects to be the first to industrialize factory-built nuclear power with near-term deployment timelines. When The Register asked about availability, their spokesperson said: "We expect the power generation portion of the system to be available as early as 2027, with the nuclear module being available to customers about 2030 based on regulatory approval." We also asked how neutrons are generated for startup and operation of the reactor module by the Neutron Driver, but Ampera is keeping this under its hat for now. As well as datacenters, defense customers will be likely takers if Ampera can produce reliable working reactors. Earlier this year, the US Department of the Air Force (DAF) announced it was looking into microreactors for three of its sites, part of a program aimed at improving energy resilience during grid outages. ®
