Advanced Structures & Composites Center

The Advanced Structures and Composites Center (ASCC) at the University of Maine was recognized as part of a nationally award-winning team advancing the future of nuclear energy construction through large-format additive manufacturing (LFAM). 

ASCC researchers were among the recipients of the 2026 SME Aubin Additive Manufacturing Case Study Award, which honors innovative, real-world applications of additive manufacturing (AM). The award was presented to a multi-institutional team led by Oak Ridge National Laboratory (ORNL), in collaboration with the ASCC, and Kairos Power. The honor was formally awarded in April, at the 2026 SME AM Awards and TCT Awards Gala in Boston. 

The award recognizes a breakthrough approach to one of the nuclear industry’s most persistent challenges: the high cost, complexity, and timeline associated with plant construction. 

ASCC’s role: large-scale 3D printing for precision nuclear infrastructure 

At the center of the project is the ASCC’s expertise in large-format additive manufacturing and digital engineering. Working alongside ORNL and Kairos Power, ASCC engineers helped design and produce specialized 3D-printed composite molds used to fabricate concrete structures for advanced nuclear reactors. 

The 3D-printed forms were integrated into a casting system, enabling the production of modular radiation shielding wall panels. Using its industrial-format polymer 3D printing capabilities, the ASCC produced monolithic full-scale molds approximately 3 feet thick and 27 feet tall using a digitally driven workflow that enabled rapid iteration and reconfiguration without rebuilding tooling. 

The molds were developed using digital models, then printed and precision-machined to meet strict construction tolerances. Critical surfaces achieved accuracy within one-sixteenth of an inch while maintaining structural integrity under the hydrostatic loads of large concrete pours. 

“This project reflects UMaine ASCC’s leadership in convergent manufacturing; integrating large-scale additive and subtractive processes, advanced materials, in-loop sensing, and a connected digital thread to accelerate the transition from design to deployment for critical infrastructure. This new technology is helping to reduce costs and accelerate the construction of Small Modular Reactors (SMRs). We are thrilled by the national recognition, and appreciate collaborating with our partners at ORNL and Kairos,” said Habib Dagher, executive director of the ASCC. 

Accelerating construction timelines while reducing cost and risk 

This approach addresses a major bottleneck in advanced reactor deployment, where concrete structures can account for up to 60 percent of construction schedule risk, particularly in SMR projects. 

The resulting composite molds are lighter than conventional steel forms, reusable, and adaptable to design changes, providing a scalable path to more efficient and cost-effective construction. This approach directly compresses the civil construction critical path, a primary driver of cost and schedule risk in advanced reactor deployment. 
The case study represents a shift from labor-intensive, custom fabrication to repeatable, factory-style digital production for safety-critical infrastructure. 
“As we work to deliver affordable energy at scale, rethinking nuclear construction is essential. Building modular prefabricated structures using digital design and advanced manufacturing can reduce risk and accelerate deployment, helping us drive down construction costs to enable widespread deployment,” said Ed Blandford, chief technology officer and co-founder of Kairos Power. 

Delivering at industry speed 

For the ASCC team, the project underscores the Center’s ability to execute at commercial scale and pace, an uncommon capability within academia. 

“We have been working on large-format AM for more than a decade, and our team has printed everything from houses to boats. This project with Oak Ridge and Kairos showcases the best of AM – rapid design to full production – while providing unique features that cannot be achieved by traditional means,” said Dr. Susan MacKay, chief materials officer at the ASCC. 

The ASCC is home to the world’s largest polymer 3D printer, capable of printing hundreds of pounds of material per hour. This capacity enabled the team to manufacture some of the largest molds ever produced, followed by precision machining and metrology verification to ensure alignment with digital designs. 

Demonstrating a scalable solution for advanced reactors  

The molds were successfully used in full-scale demonstrations for Kairos Power’s reactor program, completing multiple casting cycles without measurable loss of quality. The tooling supported these casting cycles across both cast-in-place and precast applications, validating durability and repeatability. 
The team is now exploring opportunities to scale the approach with U.S. manufacturing partners, potentially accelerating the deployment of advanced reactors nationwide.  

A model for collaboration and future infrastructure 

The project was conducted through the SM²ART (Specialized Materials and Manufacturing Alliance for Resilient Technologies) program, a public-private partnership supported by the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office (AMMTO). The initiative brings together national laboratories, universities, and industry to solve critical manufacturing challenges. 
“Oak Ridge National Laboratory brings the expertise and proven ability to rapidly assemble and execute an end-to-end domestic supply chain to meet time-critical development timelines,” said Ahmed Arabi Hassen, Group Leader, Composites Innovation Group, Oak Ridge National Laboratory. “This ORNL-led collaboration, in partnership with the University of Maine and Kairos Power, integrates materials suppliers, machine builders, and deployment partners to deliver high-performance solutions at speed and scale.” 

ASCC’s award-Winning Team

While over twenty ASCC team members were involved in the project, the following staff members represented ASCC at the award ceremony:  

The SM²ART program is funded by the Department of Energy’s Advanced Materials and Manufacturing Technologies Office. AMMTO supports a globally dominant U.S. manufacturing and industrial base for a resilient energy system and secure supply chain. Its mission is to drive and inspire innovation that transforms materials, manufacturing, and the workforce and advances America’s energy economy. 

Contact: MJ Gautrau, mj.gautrau@composites.maine.edu