The Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory, in partnership with Kairos Power and Barnard Construction, announced on July 23, 2025, a groundbreaking construction method using large-scale, 3D-printed polymer composite molds to pour concrete for the Hermes Low-Power Demonstration Reactor in Oak Ridge, Tennessee. The 10-foot-by-10-foot carbon-fiber-reinforced ABS forms, stacked three units high, enable cast-in-place construction of complex Janus shielding columns, reducing production time by 50% compared to traditional wood or steel formwork. The $150 million project, the first advanced reactor to receive a U.S. Nuclear Regulatory Commission construction permit, supports 150 jobs and bolsters East Tennessee’s 10,000-strong manufacturing workforce. Backed by the DOE’s SM2ART Moonshot Project and industry partners like Airtech and Haddy, the initiative targets a $5 billion nuclear infrastructure market, aligning with President Trump’s 10% global tariffs to prioritize domestic manufacturing. Kairos Power’s Edward Blandford stated, “This innovation accelerates nuclear deployment with precision and efficiency.”

For the precision machining industry, the Hermes project highlights the critical role of cutting fluid in manufacturing components for 3D-printed molds. Parts like mold fixtures require CNC milling with optimized cutting fluid application, typically water-based emulsions at 5–10% concentration, to achieve tolerances within ±0.001 inches and surface roughness as low as Ra 8 µin for polymer composites. 5-axis milling machines, using cutting fluid to reduce heat and tool wear, support automated production with real-time quality control. The project drives demand for local machine shops to supply precision tooling, adopting Industry 4.0 technologies like AI-driven milling and additive manufacturing. As part of a $50 billion precision manufacturing market, this initiative creates opportunities for suppliers in Tennessee, where manufacturing jobs grew 2% since 2022, strengthening nuclear supply chains.

Source:

Oak Ridge National Laboratory Press Release, July 23, 2025

Source:

Interesting Engineering

Social Media Buzz (powered by X):

X is radiating excitement over Kairos Power’s 3D-printed molds in Oak Ridge, with posts from July 23–August 3, 2025, calling it a “new dawn for nuclear tech.” Users praised the 150 jobs, with one noting, “Tennessee’s leading the nuclear renaissance!” while another tied it to “reshoring clean energy.” Some questioned the project’s cost and scalability. The X buzz glows with optimism for innovation but seeks clarity on long-term impact.

What is the Cutting Fluid?

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#KairosHermes #3DPrintedMolds #CuttingFluid #PrecisionMachining #NuclearConstruction #Reshoring