Advancing fusion materials through additive manufacturing
Freemelt
When Fusion for Energy (F4E), the European organisation responsible for Europe’s contribution to ITER, launched a Technology Development Programme (TDP) focused on tungsten materials, the Gothenburg-based company Freemelt was selected as one of only three organisations to participate. The project aims to develop advanced tungsten components for future fusion power plants, where materials must withstand extreme temperatures.
A key challenge in fusion energy is extending the lifetime of plasma-facing components exposed to intense heat and radiation.
Addressing a key fusion challenge
A key challenge in fusion energy is extending the lifetime of plasma-facing components exposed to intense heat and radiation. Improving material performance and thermal management is essential for making future fusion power plants more reliable and cost-effective.
Freemelt’s task was to develop new manufacturing methods for tungsten, a material considered critical for fusion applications due to its exceptionally high melting point of 3,422°C.
Manufacturing and materials expertise
Freemelt contributes both its electron beam powder bed fusion (E-PBF) technology and its expertise in additive manufacturing of refractory metals. The company’s 3D printing systems enable the production of high-density tungsten components in a vacuum environment and at elevated temperatures, providing unique control over material properties and microstructure.
As part of the project, Freemelt has demonstrated tungsten components with a density of 99.97%, significantly exceeding the approximately 98.7% typically achieved through conventional manufacturing methods. The company is also developing complex tungsten structures that can be infiltrated with copper alloys to improve heat transfer and extend component lifetime.
To support this work, Freemelt collaborates with Fraunhofer IGCV on advanced joining technologies for tungsten and copper alloys tailored to fusion requirements.
The new manufacturing approach offers several advantages, including improved material properties, optimised geometries, faster development cycles and enhanced thermal performance without increasing production costs. An additional benefit is the establishment of a European supply chain, from raw material to finished component.
Freemelt was selected through a competitive tender process, receiving the highest evaluation score among the participating suppliers.
Last edited 2026