ORNL Prints HIP Canisters

Scientists at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL), Oak Ridge, Tennessee, have developed a new manufacturing approach that combines additive manufacturing (AM), with hot isostatic pressing (PM-HIP) to produce large, high-performance metal components for nuclear, energy, aerospace and medical applications.

The HIP process consolidates metal powder into fully dense parts by applying high heat and pressure inside a sealed metal canister. Traditionally, these canisters are made through multiple steps such as forming, machining and welding — processes that add cost, increase lead times and can introduce defects. ORNL’s innovation replaces these conventional methods with AM printed canisters, enabling complex, near-net-shape geometries tailored to the final component while reducing material waste and production time.

Once printed, the custom canister is filled with metal powder, vacuum-sealed and processed in a hot isostatic press. The result is a structurally robust, fully dense component with minimal internal defects. The approach supports advanced alloys engineered for corrosion resistance, radiation tolerance and high-temperature stability — properties essential for next-generation nuclear reactors and hydropower systems.

To further enhance the process, ORNL researchers developed mechanics-based computational models to accurately predict shrinkage and distortion during HIP processing. These simulations reduce reliance on costly trial-and-error methods, cutting development time and improving manufacturing precision.

Building on prior PM-HIP breakthroughs, including a 2,000-pound hydropower impeller prototype produced in just two days, this work strengthens U.S. manufacturing capabilities, supports national security and opens new possibilities for large-scale, high-performance components in demanding energy applications.