Invented in 1951, a stellarator is a plasma device that relies primarily on external magnets to confine plasma. Scientists researching magnetic confinement fusion aim to use stellarator devices as a vessel for nuclear fusion reactions. The name refers to the possibility of harnessing the power source of the stars, such as the Sun. It is one of the earliest fusion power devices, along with the z-pinch and magnetic mirror. The geometric shape needed to create a stable stellarator device has been impossible to achieve until now: Type One Energy, a US-based startup has raised 50 million to build NEBULA, a giant 3D printer that can manufacture the stellarator’s complex spiraling geometry, with the goal of achieving a sustainable nuclear fusion reaction within the next decade.

The stellarator is a nuclear fusion power system that uses magnetic fields to confine ionized gas to nuclear fusion conditions using hydrogen fuel obtained from water. Its inherently practical features make it highly attractive to utilities for 24/7 baseload operations that can be deployed almost anywhere. Under development by various nations, the stellarator has been making tremendous strides in recent years towards the goal of generating surplus power.

The stellarator’s spiraling ribbon shape produces high-density plasma that’s more stable than a tokamak’s, however, its challenging geometry makes it complicated to build and extremely sensitive to imperfect conditions. This is why additive manufacturing can be a game changer in the development of tomorrow’s stellarator reactors.

Wisconsin-based Type One Energy has raised over $50 million to implement large format metal additive manufacturing in the development and production of its stellarator nuclear fusion reactors.

In addition to providing reliable and abundant power when and where it is needed, a stellarator power plant must be cost-competitive to build and operate. This is now possible due to three transformational capabilities being applied by Type One in collaboration with academic, national lab, and corporate partners.

In Type One’s plan, generative design with hybrid additive manufacturing, advanced materials, and robotic automation enables the rapid, large-scale build of highly optimized, complex-shaped, dimensionally-accurate, and defect-free stellarator components to net shape. This will be augmented by advancements in analytical theory, supercomputing and sophisticated codes to uncover previously hidden magnetic field configurations that provide optimal confinement of the plasma for the largest and most efficient power generation. In addition, new (HTS) magnets can carry over 200 times the current carrying capacity of copper wires for a more compact stellarator. It also requires less cooling power than conventional low-temperature magnets.

The commercialization campaign has three phases with technical milestones tied to two iterative stellarator builds demonstrating progressive gains in performance, simplification, and cost through the parallel application of 3D magnetic field optimization, industrial additive manufacturing, and non-planar high-temperature superconducting electromagnets.

In 2007, proof for the benefits of magnetic field shaping was first demonstrated with HSX – the world’s first optimized stellarator designed and built by Type One co-founders Prof. David Anderson and the German theorists who conceived of and designed the original quasi-helically symmetric stellarator. HSX measured 2.4 meters in diameter and cost $7.5 million US to build. Due to its optimized configuration, HSX proved superior confinement via strong reductions in neoclassical transport, a previously untamed loss mechanism that causes particles and heat to leak from the plasma. HSX continues to operate and has undergone a recent $7 million power upgrade to extend its research capabilities.

3D shaping was used to minimize neoclassical transport and it was further demonstrated with W7-X in Germany, a $1.2 billion statement of conviction for optimized stellarators by the German government. The largest experimental stellarator to date (5.5 m major radius), W7-X went online in 2015 and in 2018, it achieved a world record for stellarator fusion performance with the greatest triple product to date. With cooling system upgrades currently underway, it is targeted in 2022 to reach performance levels comparable to that of tokamaks and at run times of 30 minutes. This will be an unprecedented duration for any nuclear fusion system.

With HSX, a quasi-helical stellarator (QHS), there was a successful agreement of theory and design to the real-world experiment. QH stellarators can be built and with key physics benefits of the quasi-helical configuration demonstrated. Many of the physics properties of QHS are equivalent to the beneficial features of the tokamak, but without the plasma current instabilities, disruptions, and high recirculating power requirement.

STARBLAZER is a new stellarator currently under design by Type One that incorporates advanced optimization to dramatically reduce both neoclassical and turbulent transport – another world first. Optimizing confinement as a function of magnetic geometry addresses performance at the foundation level to avoid design pathways that would result in a much larger, less versatile, and more expensive power unit.

To extend stellarator fusion performance into the net power regime, STARBLAZER I will be designed for “ignition” (self-sustaining fusion energy output) for hours, and followed by STARBLAZER II, that will achieve “steady state” continuous operation.

To reduce build time and cost, STARBLAZER I will incorporate generative-designed and additive-manufactured components, which include the magnet assemblies, magnet support shell, heat exchanger, and vacuum vessel. In parallel, Type One is actively developing the world’s first HTS stellarator magnet with a grant from the US Department of Energy ARPA-E BETHE fusion program, in collaboration with the MIT Plasma Fusion Science Center and the University of Wisconsin at Madison.

Type One Energy is building the machine that builds the machine. The Wisconsin company is developing from the ground up NEBULA – a proprietary large format, selective high precision additive manufacturing platform made for the economical mass production of major nuclear fusion components.

The commercialization campaign has three phases with technical milestones tied to two iterative stellarator builds demonstrating progressive gains in performance, simplification, and cost through the parallel application of 3D magnetic field optimization, industrial additive manufacturing, and non-planar high-temperature superconducting electromagnets.

Phase 1 is underway and additive manufacturing initiatives include version one in-house build-out of the NEBULA platform, development of the magnet support shell, vacuum vessel, and divertor, characterize and qualifying AM metal-matrix composites for shielding with embedded functional particles for thermal, neutron flux, and fatigue resistance.

​Phase 2 will see the rapid, lean and low-cost AM build of STARBLAZER I, a high-field stellarator devoted to demonstrating ignited net power using the advanced 3D field-optimized configuration.

Phase 3 executes on the build of STARBLAZER II which incorporates extensive AM components, HTS magnets, and an integrated shield/heat exchange blanket using advanced ultra-supercritical water, tungsten carbide and F82H MMC steel. This serves as the most compact and durable radial build.

The keystone deliverable of STARBLAZER II will be the demonstration of ignited net fusion energy generating power continuously at commercial levels. This will be a a “triple net” measure that factors in the total “wall plug” input energy used by the power system, the losses from converting the nuclear fusion energy into electricity, as well as any recirculating energy fed back into the system.

STARBLAZER II will be paired with established Brayton thermal cycle technology that employs supercritical CO2 as the working medium to drive a high-heat turbine for a power conversion efficiency target of over 43%.

This market study from 3dpbm Research provides an in-depth analysis and forecast of the ceramic additive ma...

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