3D Printing with Tungsten: Russia’s Breakthrough on the Path to a Fusion Future

The Future of Fusion Energy

Russia has taken a major step toward solving one of the hardest engineering problems in fusion research. Scientists from the National University of Science and Technology MISIS and Rosatom’s R&D enterprise NPO Luch have begun mastering additive manufacturing using tungsten powder — a material considered the top candidate for the “first wall” of fusion reactors.

According to Sergey Salikhov, First Vice-Rector of MISIS, this approach has never been implemented anywhere in the world. If the technology is brought to industrial scale, it could represent not only a major engineering success but a profound breakthrough in materials science.

Why Tungsten Matters

Tungsten has exceptional properties: a record-high melting point (3422 °C), resilience under extreme radiation, and resistance to plasma erosion. These qualities make it an ideal material for components directly exposed to fusion plasma.

But working with tungsten is notoriously difficult. Its brittleness at low temperatures, tendency to crack, and high density have long made casting and machining complex shapes nearly impossible. Additive manufacturing opens a new path, enabling precise, low‑waste production. Success in Russia would strengthen technological sovereignty and contribute to global progress in fusion energy.

“Rosatom has a major program for developing new materials and technologies, including next‑generation 3D‑printing equipment. Together with NPO Luch, we have created a printer capable of synthesizing materials with controlled mechanical properties — not only from steel powders but also from tungsten. This is an extremely challenging task. No one in the world has done it, not because they do not need it, but because they lack the technology.”

Sergey Salikhov

First Vice‑Rector of MISIS

From Lab to Industry

Researchers are tuning 3D printers capable of working with ultra‑refractory metals, including tungsten, molybdenum, and niobium. This development could form a domestic supply chain for critical fusion‑energy components. In the future, the technology may be used in Russian tokamak and stellarator programs.

Internationally, if Russia demonstrates competitive quality and cost, these methods could become exportable know‑how for high‑temperature applications in aerospace, defense, and energy.

Challenges Ahead

However, announcing a milestone is only the beginning of a long road. Global studies highlight challenges such as porosity, structural nonuniformity, and brittle fracture.

All printed components must pass nuclear‑safety tests and industrial certification. Russia also faces growing competition from the U.S., EU, and China, which are developing similar technologies.

A Path to Global Leadership?

The breakthrough signals Russia’s commitment to frontier technologies. Within 1–3 years, early technical publications and prototypes are expected. Limited industrial production could follow mid‑term, especially for research reactors. In the long term, Russia could claim a leading role in the niche but crucial market for high‑temperature and fusion‑reactor components.

This tungsten 3D‑printing work is more than a technological curiosity — it is a tangible step toward clean, safe, and virtually limitless fusion power.