Nuclear-Grade Additive Manufacturing Addresses Obsolescence in Canadian Reactor Fleets

Kinectrics and Burloak Advance Nuclear-Grade Additive Manufacturing

Canadian firms Kinectrics and Burloak Technologies have reached a key milestone in nuclear manufacturing. They successfully qualified a nuclear-grade hydraulic manifold using metal Additive Manufacturing (AM). This achievement helps solve part obsolescence in aging reactor fleets like CANDU. It also supports new nuclear systems, including Small Modular Reactors (SMRs).

The component is a pressure-retaining hydraulic manifold made from 17-4 PH stainless steel. Burloak printed it at their certified AM facility using an EOS M290 PBF-LB machine. Thanks to AM, the part includes internal flow channels that improve performance. Such features are difficult or impossible with traditional methods.

Post-processing included NADCAP-accredited heat treatment and five-axis CNC machining. The part also underwent ISO 17025-certified lab testing and advanced metrology checks. These steps ensured the part met nuclear-grade mechanical and safety standards.

David Marttila of Kinectrics said the process proved AM can meet nuclear service standards. He noted this success applies the same safety and performance rigor as conventional parts. The project solves part scarcity and sets a model for using AM in regulated nuclear sectors.

AM Innovation Targets CANDU and SMR Reactor Applications

While the initial focus lies in replacing legacy parts for Canada’s CANDU reactor fleet, the broader aim targets next-generation nuclear designs. AM’s capacity to streamline complex assemblies and optimize fluid dynamics supports the goals of SMR and advanced reactor programs.

Burloak’s Jason Ball emphasized that on-demand AM production is not just a replacement solution—it’s a catalyst for innovation. The flexibility of AM allows engineers to rethink component designs, reduce part counts, and deliver enhanced performance over traditionally manufactured parts.

By combining design freedom with strict quality controls, this AM initiative is reshaping how nuclear operators approach component certification, prototyping, and lifecycle management. The partnership also contributes to building a standards framework for future nuclear-grade AM parts in Canada.

SuperMetalPrice Commentary:

Kinectrics and Burloak Technologies have made a strategic move that could reshape nuclear component supply chains. As aging reactors confront part obsolescence and SMRs demand flexible engineering solutions, Additive Manufacturing emerges as a vital enabler. By validating AM within such a high-regulation industry, these companies are setting the stage for broader adoption across global nuclear markets. Expect other nations to monitor this initiative closely as they seek scalable, cost-effective alternatives for maintaining and upgrading reactor fleets.