US 2026/0045376 A1Published application

System & method for 3-d printing a nuclear reactor

AssigneeLast Energy Inc.

InventorsBret Kugelmass, Mark G. Blomstrom, Jonathan R. Ritchie, Christopher D. Muscari, Elizabeth M. May

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Abstract

One variation of a system includes a pressure vessel: formed of a set of structural layers arranged in a column; defining a primary internal volume within the column; defining a set of infrastructure receptacles containing a heat exchanger and a pump and arranged above the primary internal volume within the column; defining a primary coolant circuit extending between the primary internal volume and the set of infrastructure receptacles within the column; and defining a secondary coolant circuit extending within the wall and adjacent and fluidly isolated from the primary coolant circuit. The system also includes: a nuclear fuel arranged within the primary internal volume; a primary coolant circulating between the nuclear fuel and the primary coolant circuit; and a secondary coolant circulating between the secondary coolant circuit and an external power generation system. The heat exchanger is configured to transfer thermal energy from the primary coolant to the secondary coolant.

Claims20

Dependent claims

A system comprising:

a pressure vessel:
comprising a wall formed of a set of structural layers arranged in a column;
defining a primary internal volume within the column;
defining a set of infrastructure receptacles arranged above the primary internal volume within the column;
defining a primary working fluid circuit extending between the primary internal volume and the set of infrastructure receptacles within the column;
and
defining a secondary working fluid circuit adjacent and fluidly isolated from the primary working fluid circuit;
a nuclear fuel arranged within the primary internal volume;
a primary working fluid:
sealed within the pressure vessel;
and
circulating between the nuclear fuel and the primary working fluid circuit;
a secondary working fluid circulating between the secondary working fluid circuit and an external power generation system;
a heat exchanger:
arranged within a first infrastructure receptacle in the set of infrastructure receptacles;
fluidly coupled to the primary working fluid circuit;
and
configured to transfer thermal energy from the primary working fluid to the secondary working fluid;
and
a set of liners:
comprising a set of interior liners arranged within the pressure vessel and lining interior surfaces of the wall facing the primary internal volume and the set of infrastructure receptacles;
comprising an exterior liner arranged about an exterior surface of the wall;
and
configured to yield against the wall under internal pressure to form a seal between the wall and the primary internal volume.

21 more elements

A method for manufacturing a pressure vessel comprising:

during a first assembly period:
locating a base structural layer, in a set of structural layers, on a build surface;
arranging a first subset of structural layers, in the set of structural layers, in a column to form a reactor section of the pressure vessel defining a primary internal volume configured to house a nuclear fuel, comprising, for each structural layer in the first subset of structural layers:
applying an interstitial layer to a surface of the structural layer;
coaxially and radially aligning the structural layer to the base structural layer;
and
affixing the structural layer to a preceding structural layer, in the first subset of structural layers, in the column via the interstitial layer interposed between the structural layer and the preceding structural layer, the first structural layer coaxially aligned to the preceding structural layer and the base structural layer;
heating the reactor section of the column to a first target temperature to cure interstitial layers between structural layers in the first subset of structural layers;
and
applying a first set of liners to interior walls of the reactor section encapsulating the primary internal volume, the first set of liners configured to form a seal between the interior wall and the primary internal volume;
and
during a second assembly period succeeding the first assembly period:
arranging a second subset of structural layers, in the set of structural layers, in the column to form an equipment section of the pressure vessel defining a set of infrastructure receptacles, comprising, for each structural layer in the second subset of structural layers:
applying an interstitial layer to a surface of the structural layer;
coaxially and radially aligning the structural layer to the first subset of structural layers;
and
affixing the structural layer to a preceding structural layer, in the second subset of structural layers, in the column via the interstitial layer interposed between the structural layer and the preceding structural layer, the structural layer coaxially aligned to the preceding structural layer, the first subset of structural layers, and the base plate;
heating the equipment section of the column to a second target temperature to cure interstitial layers between structural layers in the second subset of structural layers;
applying a second set of liners to interior walls of the equipment section lining the set of infrastructure receptacles;
installing a heat exchanger in a first infrastructure receptacle in the set of infrastructure receptacles;
and
installing a pump in a second infrastructure receptacle, in the set of infrastructure receptacles, above the first infrastructure receptacle within the column;
and
during a third assembly period succeeding the second assembly period;
arranging a third subset of structural layers, in the set of structural layers, in the column to form a condensation section of the pressure vessel defining a set of slots configured to enable airflow through the column to promote convection cooling, comprising, for each structural layer in the third subset of structural layers:
applying an interstitial layer to a surface of the structural layer;
coaxially and radially aligning the structural layer to the second subset of structural layers;
and
affixing the structural layer to a preceding structural layer, in the third subset of structural layers, in the column via the interstitial layer interposed between the structural layer and the preceding structural layer, the structural layer coaxially aligned to the preceding structural layer, the second subset of structural layers, the first subset of structural layers, and the base plate;
and
heating the condensation section of the column to a third target temperature to cure interstitial layers between structural layers in the third subset of structural layers.

28 more elements

A method for manufacturing a pressure vessel comprising:

during a first assembly period:
locating a base structural layer, in a set of structural layers, on a build surface;
arranging a first subset of structural layers, in the set of structural layers, in a reactor section of a column defining a primary internal volume configured to house a nuclear fuel, comprising, for each structural layer in the first subset of structural layers:
applying an interstitial layer to a surface of the structural layer;
coaxially and radially aligning the structural layer to the base structural layer;
and
affixing the structural layer to a preceding structural layer, in the first subset of structural layers, in the column via the interstitial layer interposed between the structural layer and the preceding structural layer, the first structural layer coaxially aligned to the preceding structural layer and the base structural layer;
applying a first set of liners to interior walls of the reactor section encapsulating the primary internal volume, the first set of liners configured to form a seal between the interior wall and the primary internal volume;
and
during a second assembly period succeeding the first assembly period:
arranging a second subset of structural layers, in the set of structural layers, in an equipment section of the column defining a set of infrastructure receptacles, comprising, for each structural layer in the second subset of structural layers:
applying an interstitial layer to a surface of the structural layer;
coaxially and radially aligning the structural layer to the first subset of structural layers;
and
affixing the structural layer to a preceding structural layer, in the second subset of structural layers, in the column via the interstitial layer interposed between the structural layer and the preceding structural layer, the structural layer coaxially aligned to the preceding structural layer, the first subset of structural layers, and the base plate;
applying a second set of liners to interior walls of the equipment section lining the set of infrastructure receptacles;
installing a heat exchanger in a first infrastructure receptacle in the set of infrastructure receptacles;
and
installing a pump in a second infrastructure receptacle, in the set of infrastructure receptacles, above the first infrastructure receptacle within the column.

16 more elements

Dependencies are inferred from the claim text.

Facts

Application: 19/356,880Filed 13 Oct 2025
Priority: 20 Oct 2023
Published: 12 Feb 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification12 codes

G21C 13/0875
Metallic vessels: tube-type vessels, e.g. for not essentially pressurised coolants
G21C 11/085
Consisting of one or more metallic layers: consisting exclusively of several metallic layers
G21C 11/088
Thermal shields; Thermal linings, i.e. for dissipating heat from gamma radiation which would otherwise heat an outer biological shield ; Thermal…:…
G21C 13/02
Pressure vessels; Containment vessels; Containment in general: details

Family

Application63/545,044Us provisional application · filed 20 Oct 2023
Application18/921,964Continuation · filed 21 Oct 2024
Application19/301,579Continuation in part · filed 15 Aug 2025
Application19/356,880Continuation in part
Application19/301,579Continuation
US 12,412,674 B2Related patent
US 2025/0132064 A1Published application
US 2026/0038704 A1Published application
US 2026/0045376 A1This patent

From the US filing history. Foreign family members aren’t listed.