Additive Manufacturing Speeds Target Fabrication for Fusion Energy Experiments
Engineers at Lawrence Livermore National Laboratory have utilized two-photon polymerization to revolutionize the production of submillimeter-scale components for the National Ignition Facility. As TechXplore Engineering reports, this additive manufacturing shift allows for the creation of complex target geometries that were previously impossible to manufacture, cutting production timelines from ten days to just twenty-four hours.
Context from Industry Pulse
The adoption of two-photon polymerization at Lawrence Livermore National Laboratory addresses a critical bottleneck in high-energy-density physics: the manual complexity of target assembly. With the National Ignition Facility limited to roughly 300 experiments annually, every component must undergo rigorous testing at secondary sites like the Jupiter Laser Facility to ensure it does not cause backscatter damage to optics. By integrating features like guide rails directly into the 3D-printed geometry, engineers reduce assembly errors and meet the stringent tolerances required for discovery science. This technical leap from ten-day manual fabrication to single-day automated printing enables more rapid iteration of experimental designs, directly supporting missions in both national security and ion fast ignition research.
Fabricating targets for high-energy-density physics experiments requires extreme precision to manage the intense laser energy used at the National Ignition Facility. Traditionally, components like the compound parabolic concentrator were produced through a multi-step cycle involving diamond-turning copper mandrels, gold coating, and chemical leaching. This labor-intensive workflow often took ten days to complete a single part. TechXplore Engineering notes that the transition to two-photon polymerization, an additive technique using tightly focused lasers, has condensed this entire process into one day.
The new manufacturing approach addresses long-standing challenges regarding scale and surface quality. Previous additive methods struggled with feature sizes and required stitching multiple prints together, which created rough surfaces that could damage expensive laser optics through unwanted reflections. By using a laser focal spot smaller than one micron, engineers can now print single-assembly components with the necessary geometric tolerances and smoothness to function safely within the beamlines.
Beyond speed, the technology provides significant design freedom for experimental physics. For a September 2026 discovery science campaign focused on ion fast ignition, engineers designed a concentrator with integrated guide rails. This modification allowed the tiny component to be slid accurately into a gold cone, a feat described as impossible under former assembly constraints. The successful fielding of these parts suggests that additive manufacturing can meet the rigorous characterization standards required for national security data collection.
Looking forward, the engineering team is investigating further applications for this high-precision printing method. According to TechXplore Engineering, future projects may include the development of fuel capsules containing internal lattice structures. these specialized architectures could potentially hold wetted foams, offering a novel method for stabilizing the fuel layers used during inertial confinement fusion implosions.
The Industry Pulse Bottom Line
Transitioning to two-photon polymerization allows for the rapid prototyping of fusion targets with sub-micron precision, reducing production cycles by 90% while enabling complex, off-axis geometries that were previously unachievable through traditional diamond-turning methods.