ORNL and INL Partner to Develop Process for 3D-Printed Pressure Vessels

In August 2026, Oak Ridge National Laboratory and Idaho National Laboratory partnered to develop a process for wire arc 3D printing of industrial pressure vessels that are used in nuclear and chemical processing applications. According to Robert Wagner, ORNL associate laboratory director for energy science and technology, their partnership with industry to present and validate advanced production technologies will assist them in reducing risk, speeding up deployment operations, and strengthening domestic supply chains, which is important for America's energy sector.

A pressure vessel is an important component in a nuclear reactor, as they need to survive adverse conditions, which demand extreme toughness and structural strength. The process of forging is used conventionally, but the energy needs of the U.S. are increasing, and forging capacity is not able to keep up with it. The wire arc additive manufacturing technique makes use of a robotic welding arm and wire feedstock to 3D print components. It is used to print large components and provides better pace and flexibility than forging.

Scientists at the Manufacturing Demonstration Facility of ORNL conducted a demonstration in which they used wire arc 3D printing to develop a small nuclear pressure vessel. Both national labs jointly announced that this demonstration successfully showed the capability to print a large closed vessel with a steel alloy. The team used ORNL’s MedUSA platform, which utilizes 3 synchronized robotic arms to manufacture complex parts by melting wire with electric arcs. 

This project brings together INL’s prowess in manufacturing technologies for nuclear reactors and digital engineering and ORNL’s management experience in additive manufacturing and the characterization of printed parts. According to Jorgen Rufner, INL group lead for advanced manufacturing and a specialist in harsh-environment materials, this venture brings together the prowess of both labs to combine AI and data science with advanced 3D printing to enable real-time assessment of a particular component.

Impact on the Energy and Power Industry

According to Precedence Research, the partnership between ORNL and INL is expected to positively impact the energy and power industry. Many countries are requiring more and more energy for various next-generation technologies, and they need safe and reliable sources of power. Nuclear energy has the potential to fulfill those needs as it has very high power density. There are significant uranium and thorium deposits, which are used as fuel in nuclear reactors. The wire arc 3D printing process enables companies to manufacture high-pressure industrial vessels at a much faster rate than forging.

Impact on the Pressure Vessels Market

The global pressure vessels market size accounted for USD 26.35 billion in 2025 and is predicted to reach around USD 56.67 billion by 2035, growing at a CAGR of 7.96% from 2026 to 2035.

According to Precedence Research, the partnership between ORNL and INL is expected to benefit the pressure vessels market. Pressure vessels find applications in various sectors, as they are used in industries to perform routine production workflows that require much higher pressure than ambient pressure. The wire arc 3D printing process enables companies to produce pressure vessels at a much faster rate than the conventional forging process.

Impact on the 3D Printing Market

The global 3D printing market size was estimated at USD 29.29 billion in 2025 and is predicted to increase from USD 34.85 billion in 2026 to approximately USD 152.72 billion by 2035, expanding at a CAGR of 17.96% from 2026 to 2035.

According to Precedence Research, the partnership between ORNL and INL is expected to positively impact the 3D printing market. 3D printing is being rapidly adopted to manufacture large and sophisticated components. Industrial pressure vessels require precision manufacturing, as the vessel walls are exposed to high-pressure conditions for extended periods of time. Advanced manufacturing machinery has enabled the use of 3D printing techniques to produce large, sophisticated industrial components. 

About Oak Ridge National Laboratory

Oak Ridge National Laboratory is the largest science and energy laboratory for the U.S. Department of Energy. ORNL performs research activities in a wide range of sectors to resolve the energy, environment, and security issues of the U.S. The laboratory conducts research on various technical subjects, which include supercomputing, neutron science, fusion and fission, isotopes, etc.

About Idaho National Laboratory

Idaho National Laboratory is a prominent research institution that drives innovation in the fields of nuclear and renewable energy and security solutions. In 1949, the U.S. Atomic Energy Commission announced that it planned to build a National Reactor Testing Station on the Naval Proving Ground in Idaho. Since its establishment, 55 reactors have been built in the 890-square-mile campus of INL.