ROSATOM launches its first Additive Technologies Center in Moscow

On December 23, 2020, Rusatom – Additive Technologies (RusAT, an enterprise of TVEL Fuel Company and ROSATOM’s integrator for additive manufacturing business) opened its first Additive Technologies Center (ATC) at the site of the Moscow Polymetal Plant.


TVEL President Natalia Nikipelova and RusAT Director General Mikhail Turundaev at the official opening of the ATC

ROSATOM’ ATC in Moscow has been created as the first model of a facility combining development, engineering and manufacturing. It is unique for its combination of the shop-floors for 3D printers assembling, printing, post-processing, as well as the laboratory for product research and sample testing. Thus, the engineers of RusAT will be able to check the adopted design and technological solutions immediately after equipment launch and promptly make adjustments to its design.

This is the only additive technologies center in Russia operating domestic equipment. It is aimed mainly at testing additive manufacturing technologies and demonstration of their capabilities for industrial enterprises.

The center is equipped with 3D printers of ROSATOM’s own design and production, such as Rusmelt 300M, Rusmelt 600M and Rusmelt 600 RM for printing with metal powders using selective laser melting technology (SLM). These printers run on Russian software and have parameters and characteristics that meet international standards. In addition, the Rusmelt 600M printer has a 600×600 mm construction area, which allows printing products with unique dimensions for the applied SLM-technology.

The second stage of the ATC facility will house complex machines for 3D printing with metal powders and photopolymers using the technologies of selective laser sintering (SLS) and Stereolithography (SLA). The range of testing and auxiliary equipment also will be expanded.

“Opening of the first Additive Technologies Center underlines the role of ROSATOM in creating a new technological paradigm in our country. This is an extraordinary milestone not just for the nuclear industry, but on a national scale as well. There is a lot of work ahead to create a whole network of such centers, primarily in the cities and regions of Rosatom enterprises operation. The next such center will be established in Novouralsk on the basis of NPO Centrotech, another enterprise of TVEL Fuel Company. Development and application of these technologies has a great meaning for the entire nuclear industry. We have solutions for using additive manufacturing, from separate elements of some products to essential supplies of equipment”, said Alexey Likhachev, Director General of ROSATOM.

“It is fundamentally important that it is the first such facility in Russia operating Russian-made equipment. All of it has was developed by our engineers. The equipment of the 3D-printers was manufactured at NPO Centrotech, the complete machines have been assembled at the site in Moscow. They run on Russian software. The first installation for the production of powders for 3D-printing has been recently launched at NPO Centrotech. ROSATOM has chosen the path of developing the full product line of equipment and services for additive manufacturing, being a manufacturer and a customer at the same time. This center features a fully 3D-printed anti-debris filter for a nuclear fuel assembly. It required fewer materials than traditional manufacturing, and it has a design that would be impossible to reproduce with other methods. By introducing additive technologies in our own business, we show an example for other industries. In fact, we are creating another new industry in Russia with its own centers, expertise, staff and linked universities”, commented Natalia Nikipelova, President of TVEL JSC.

“The First Additive Technologies Center of ROSATOM is a pilot platform where we will develop the best technological proposals and business solutions for our clients. After debugging the printing modes, we will take orders. By the end of 2021, we plan to launch a full production cycle for AM products. At the current stage of the AM market, the equipment that has been installed at the ATC and will be installed in 2021, will completely cover the needs of our customers. As for financial indicators, after launch of the second stage, the planned revenue of CAT would exceed 300 million rubles by 2030”, said Mikhail Turundaev, Director General of RusAT.

For reference:

RusAT LLC (an enterprise of the TVEL Fuel Company of ROSATOM) is a specialized company – an integrator of the nuclear industry in the field of additive technologies (three-dimensional printing). The company’s activities are focused on four key areas: the production of a line of 3D printers and their components, the creation of materials and metal powders for 3D printing, the development of integrated software for additive systems, as well as the provision of services for 3D printing and the introduction of additive technologies into production (including, in terms of the organization of production centers). https://rusatom-additive.ru/en/rusatom/

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. https://www.tvel.ru/en/

ROSATOM is a global actor on the world’s nuclear technology market. Its leading edge stems from a number of competitive strengths, one of which is assets and competences at hand in all nuclear segments. ROSATOM incorporates companies from all stages of the technological chain, such as uranium mining and enrichment, nuclear fuel fabrication, equipment manufacture and engineering, operation of nuclear power plants, and management of spent nuclear fuel and nuclear waste. Nowadays, ROSATOM brings together about 350 enterprises and organizations with the workforce above 250 K. https://www.rosatom.ru/en/

Rosatom has developed its own laser systems product line for 3D printers

Specialists of All-Russia Research Institute of Technical Physics (VNIITF) have developed and manufactured prototypes of lasers with a power of 200, 400, 700 and 1000 W to be used in SLM printers.

The development was carried out within the framework of R&D «Lasers», which is supervised by the integrator «Rusatom – Additive Technologies» (RusAT, an enterprise of TVEL Fuel Company).

The model range of laser sources will undergo a set of tests at RFNC-VNIIEF, after which they will be sent to RusAT’s Additive Technologies Center at the site of the Moscow Polymetal Plant for further testing on RusMelt 300M and RusMelt 600M 3D printers.

By the end of 2021, it is planned to carry out a full cycle of tests of laser sources in accordance with the requirements of State Standards and prepare the line for serial production.

«Laser system is one of the key components of an SLM printer along with machinery components and software. The created line of lasers is an opportunity to fully provide the additive manufacturing of Rosatom with its own developments, which is necessary for the business stability and independence from external suppliers. Moreover, in the future, RusAT will be able to accept orders for laser products of this line», – noted Mikhail Turundaev, CEO of RusAT.

For reference:

RusAT LLC (an enterprise of the TVEL Fuel Company of ROSATOM) is a specialized company – an integrator of the nuclear industry in the field of additive technologies (three-dimensional printing). The company’s activities are focused on four key areas: the production of a line of 3D printers and their components, the creation of materials and metal powders for 3D printing, the development of integrated software for additive systems, as well as the provision of services for 3D printing and the introduction of additive technologies into production (including, in terms of the organization of production centers). https://rusatom-additive.ru/en/rusatom/

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. https://www.tvel.ru/en/

ROSATOM is a global actor on the world’s nuclear technology market. Its leading edge stems from a number of competitive strengths, one of which is assets and competences at hand in all nuclear segments. ROSATOM incorporates companies from all stages of the technological chain, such as uranium mining and enrichment, nuclear fuel fabrication, equipment manufacture and engineering, operation of nuclear power plants, and management of spent nuclear fuel and nuclear waste. Nowadays, ROSATOM brings together about 350 enterprises and organizations with the workforce above 250 K. https://www.rosatom.ru/en/

RusAT is now a member of ASTM International

The industry integrator Rusatom – Additive Technologies (RusAT; an enterprise of Rosatom Fuel Company TVEL) is cultivating international cooperation in additive manufacturing – the company has become a member of ASTM International. It is a recognized authority in global standardization and technical documentation for various industries.

RusAT specialists focuses on the ASTM Additive Manufacturing Committee F42. To date, the committee includes representatives from more than 20 countries, involved 8 technical subcommittees. ASTM F42 committee has fully developed 26 standards and committee’s experts took part in the development of more than 40 standards.

“ASTM Additive Manufacturing Committee F42 membership will help us to conduct standardization work most efficiently. For example, we will be able to issue Russian standards harmonized with international ones. Standards harmonization is one of the ways to reduce the barriers to our products entering foreign markets”, – said Mikhail Turundaev, Director General of RusAT.

Standards issued by ASTM International are widely used in many industries, such as the oil & gas and metallurgy. ASTM standards provides the groundwork for competitive and safe production and are the foundation of own standards, contracts, laws and regulations in many countries around the world. ASTM supports about 12,000 standards as of today.

Earlier this year, RusAT specialists received the official status of representatives from Russia in the ISO / TC 261 “Additive Manufacturing” technical committee of the International Organization for Standardization (ISO).

For reference:

RusAT LLC (part of TVEL Fuel Company of Rosatom) is a specialized company – an integrator of the nuclear industry in additive manufacturing (AM). The company’s activities are focused on four key areas: 3D printers and their components production; creation of materials and metal powders for AM; development of software suite for additive manufacturing; outsourcing 3D printing services for clients and additive manufacturing introduction into production (including the organization of AM production centers).

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. www.tvel.ru 

Rosatom starts production of two new multilaser 3D printers

As ordered by Rusatom – Additive Technologies (RusAT), NPO Centrotech (both are enterprises of the Rosatom Fuel Company TVEL) started the production of two machine kits of multi-laser 3D printers with a production size of 600x600x500 mm development by Rosatom.

Key advantages of this model are its compact size, large construction area, built-in powder regeneration system and access to the construction platform in a separate chamber without depressurization the main compartment. The updated open-source software suite allows to work both in automatic mode without additional settings (depending on the default metal powder used), and selecting fusion parameters manually when using new materials. In addition, the design of this model uses the original powder material loading system, which eliminates the idling of the carriage (powder spreader) when constructing the part, thus reducing manufacturing time.

The device is optionally equipped with various process control systems.

Regarding the technological capabilities, this 3D printer embodied the R&D experience of Russian 3D printers: a multi-laser (3-laser) optical system, a 3-axis scanning system with the ability to compensate for the focus of the laser beam in any construction area automatically, which can significantly increase the manufacture performance. The printing time of one item is also reduced due to the simultaneous use of lasers in various modes of material fusion – drawing the contours of the part and hatching the internal volume of the part with a defocused laser beam.

In September, NPO Centrotech will ship this machine kits, control system and a hydraulic system to Moscow for final assembly and adjustment by RusAT. Assembled 3D printers will be used at the Additive Technologies Center of the State Atomic Energy Corporation Rosatom in Moscow.

For reference:

The first Russian experimental 2-powder 2-laser 3D printer, created by Rosatom, was put into trial operation at NPO Centrotech LLC. This is the result of the joint work of NPO Centrotech, Ural Electrochemical Plant and RPA CNIITMASH, as well as several other enterprises and research institutes of Rosatom and  the Ministry of Education and Science. This efforts became a basis for establishing the industry integrator – Rusatom – Additive Technologies (RusAT).

RusAT LLC (part of TVEL Fuel Company of Rosatom) is a specialized company – an integrator of the nuclear industry in additive manufacturing (AM). The company’s activities are focused on four key areas: 3D printers and their components production; creation of materials and metal powders for AM; development of software suite for additive manufacturing; outsourcing 3D printing services for clients and additive manufacturing introduction into production (including the organization of AM production centers).

NPO Centrotech LLC is an enterprise of the Novouralsk industrial site, part of the Fuel Company of Rosatom TVEL. It has unique competencies in the nuclear, military, aerospace, oil & gas and instrument-making fields. It specializes in the production of gas centrifuges for the enrichment of uranium, as well as general industrial products. The company implements a full technological cycle of products: from development to disposal.

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. www.tvel.ru

Rosatom starts 3D printing of valves for medical ventilators

Rusatom – Additive Technologies company (RusAT LLC; part of the TVEL Fuel Company of Rosatom) has made prototypes and is ready to start 3D printing of Venturi valves used in medical respiratory ventilators.

The need for these components has greatly increased due to the coronavirus COVID-19 pandemic. RusAT’s production facilities could produce about 300 valves per week. Biocompatible polymer used in additive manufacturing; the product does not require additional processing.

Venturi valves are used with masks for dosed oxygen therapy and provide controlled concentrations of oxygen supplied. They’re used within a few hours and require replacement afterwards, being, in fact, a consumable. Some countries were faced with shortage of valves, which, in some cases, was solved with additive manufacturing.

“Russian nuclear industry enterprises are mobilizing their resources to confront the coronavirus pandemic. All Rosatom companies, involved in medical industry, are looking for manufacturing and intellectual capabilities for prompt production tune for equipment and supplies that medics need to fight coronavirus. We sent information on Venturi valves production capabilities to the Russian Ministry of Health, Ministry of Emergencies, Ministry of Defense and Rospotrebnadzor. If necessary, valve production can be started as soon as possible”, said Alexey Likhachev, Director General of Rosatom State Corporation.

RusAT Director General Mikhail Turundaev noted: “Our company, as Rosatom additive manufacturing industry integrator, has explored the opportunity of printing valves for ventilators. We’ve made prototypes and ready to start production for further delivery of valves to medical institutions. In addition to valves, breathing masks, respirators and other medical devices can also be produced using 3D printing”.

For reference:

RusAT LLC (part of TVEL Fuel Company of Rosatom) is a specialized company – an integrator of the nuclear industry in additive manufacturing (AM). The company’s activities are focused on four key areas: 3D printers and their components production; creation of materials and metal powders for AM; development of software suite for additive manufacturing; outsourcing 3D printing services for clients and additive manufacturing introduction into production (including the organization of AM production centers).

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. www.tvel.ru 

Rosatom experts joined ISO Additive Manufacturing Committee

The experts of Rusatom – Additive Technologies (RusAT LLC; part of the TVEL Fuel Company of Rosatom) received official status of Russian Federation representatives on the ISO/TC 261 Additive Manufacturing Technical Committee of the International Organization for Standardization ISO. RusAT is a designated roadmap operator for the “Additive manufacturing” branch of the “Technologies for new materials and substances” program in Russia.

“At the initial stage of mastering the additive manufacturing, development of national and international standards plays an important role and provides efficiency in new technologies’ introduction. It is substantial that Rosatom representatives are not only involved in national standardization regarding additive manufacturing, but also in international work in this area”, said Mikhail Turundaev, CEO of RusAT.

Embedded in ISO/TC 261, RusAT employees are representing Russian stance, included in working groups to develop standards, considers draft of international standards at various stages and make their proposals. Russia has the status of a full member of this technical committee and can influence the development of ISO standards by voting on various issues of the committee.

Standardization in the field of additive manufacturing concerns their terms and definitions, production processes, hardware and software, the properties of raw materials, personnel requirements, and other issues that are important in ensuring product quality. Issues of international standardization lay the groundwork for global cooperation; therefore RusAT pays significant attention to this topic.

For reference:

International Organization for Standardization (ISO) is a recognized organization that develops and publishes international standards. ISO is an independent non-governmental organization with national standardization bodies involved. International standards foster innovation and global technology challenges.

RusAT LLC (part of TVEL Fuel Company of Rosatom) is a specialized company – an integrator of the nuclear industry in additive manufacturing (AM). The company’s activities are focused on four key areas: 3D printers and their components production; creation of materials and metal powders for AM; development of software suite for additive manufacturing; outsourcing 3D printing services for clients and additive manufacturing introduction into production (including the organization of AM production centers).

TVEL Fuel Company of Rosatom incorporates enterprises for the fabrication of nuclear fuel, conversion and enrichment of uranium, production of gas centrifuges, as well as research and design organizations. It is the only supplier of nuclear fuel for Russian nuclear power plants. TVEL Fuel Company of Rosatom provides nuclear fuel for 73 power reactors in 13 countries worldwide, research reactors in eight countries, as well as transport reactors of the Russian nuclear fleet. Every sixth power reactor in the world operates on fuel manufactured by TVEL. www.tvel.ru

NPO Centrotech shipped machine kits for 2-laser 3D-printers

NPO “Centrotech” (an enterprise of the Rosatom Fuel Company TVEL in Novouralsk, Sverdlovsk Region), shipped two machine sets of 2-laser 3D printers with 300×300 working area. The customer is the industrial integrator RusAT for further development. In addition to machine kits, a control system and a gas-hydraulic system were also sent to the company.

The new model has a more compact size compared to the prototype of the first Russian 2-powder 2-laser 3D-printer, which will significantly save the workspace. Among the advantages of this model is advanced software suite that allows working both in automatic modes without additional settings depending on the metal powder used, as well as in modes of selecting fusion parameters when using new materials. In addition, this printer lacks idling of the carriage – powder spreader, which reduces the manufacturing time of the part.

In terms of its technological capabilities, the novelty embodied the experience of Russian 3D-printers: a 2-laser system, a 3-axis scanning system, which can increase productivity by more than 60%. Printing one product takes less time, also due to the possibility of simultaneous use of two lasers in different modes of fusion of the material – drawing the contours of the part and hatching the internal volume of the part with a defocused laser beam.

The assembled models are planned to be placed in Moscow at the Additive Technologies Center of the State Atomic Energy Corporation Rosatom. There the control system & software suite will be installed, and printers will be put into operation.

The first Russian 2-powder 2-laser 3D-printer is put in trial operation in Rosatom

The first Russian 2-powder 2-laser 3D-printer, created by Rosatom specialists, is put into trial operation at the site of NPO “Centrotech” (an enterprise of the Rosatom Fuel Company TVEL in Novouralsk, Sverdlovsk Region). This is the result of the joint work of NPO “Centrotech”, Ural Electrochemical Plant and RPA “CNIITMASH”, as well as several other enterprises and research institutes of Rosatom, the efforts of which are consolidated by the industry integrator – Rusatom – Additive Technologies (RusAT).

Compared to 1-laser, the performance of a 2-laser printer is increased by 60%. Printing one product takes less time, and due to the possibility of using two lasers simultaneously, the installation allows to use one of them for various technological methods that will improve the characteristics of materials.

The fundamental difference between the development and the existing printers on the market is that it is polypowder. A unique powder regeneration system will allow in parallel with the printing process to separate two types of powders that differ in fractional composition, returning the regenerated powder back to the printing unit. This significantly reduces the consumption of powders and, as a result, the cost of products.

Currently, RusAT has sent more than twenty applications for the manufacture of products using laser fusion technology to the NPO “Centrotech”. In particular, printing standard samples from nickel alloy. Technology for printing the flange of an electrochemical generator is being developed.

In addition, RusAT has ordered the assembly of 3D-printers at NPO “Centrotech”. The first machines are planned to be delivered in Moscow, at the Additive Technologies Center of the State Atomic Energy Corporation Rosatom, before the end of 2019.

Chepetsk Mechanical Plant to become a ground for production of materials for 3D printers

Chepetsk Mechanical Plant (ChMZ JSC, a member of the Fuel Company TVEL of Rosatom) has been assigned to be an industrial site for the production of titanium alloy powders for 3D-printers. This decision was made at the “Rosatom – Additive Technologies Today” conference – first of its kind in the Russian nuclear industry. The decisive factors in this decision – are the undoubted advantages of the enterprise, which operates with the full production cycle of titanium and includes Central Plant Laboratory, equipped with modern equipment and experience, necessary for the certification of metal powders.

The scope of titanium powders in additive manufacturing is very wide: from “growing” the components of aircraft engines to the manufacturing of medical implants. The industry integrator, Rusatom – Additive Technologies, in collaboration with research institutes and using materials from ChMZ plans, to begin pilot production of titanium medical prostheses in 2020. 3D-printed samples have already passed pre-clinical trials. Thanks to the project, medical professionals will be able to get an individual and perfectly suitable implant for the patients, created on the basis of his tomogram in the shortest possible time.

Another project of ChMZ with AM is the study of features of 3D-printing with metal wire. The plant executes R&D works together with the Perm National Research Polytechnic University.

“Today, additive manufacturing needs suppliers who are able to quickly and efficiently produce unique materials for certain 3D-printing technologies. The competencies of the Chepetsk Mechanical Plant allow us to promptly adjust the chemical composition of alloys, which is especially important for our partners. The entry of ChMZ into the cluster of additive manufacturing combined with leading research and production companies of the country is a powerful reserve for the future enterprise,”– said Konstantin Shashkeev, project manager for new products of ChMZ.

3D-printing technologies are actively used in power engineering, instrumentation, aviation, space industry, where there is a high demand for products of complex geometry. According to experts, by 2025 the global additive manufacturing market will reach $45 billion. Today, there are about 100,000 3D-printers in the world, more than 5,000 of them are for metal printing. The annual growth in the production of industrial printers entails the need for printing materials, the manufacture of which is one of the strategic directions of the state program for the development of new production technologies in Russia.

Rosatom has established an industry integrator for additive manufacturing development

Rosatom State Corporation has established the new specialized company Rusatom – Additive Technologies (RusAT LLC) based on the TVEL Fuel Company. Its mission is to become a single industry integrator for the development of a new business – additive manufacturing (3D-printing).

The new company, which management began work in February 2018, will focus on four key areas: the production of a line of 3D-printers and their components, the creation of materials and metal powders for 3D-printing, the development of software suite for additive systems, as well as outsourcing on 3D printing services and the introduction of additive manufacturing in production (including the organization of production centers).

Production facilities for the production of equipment and materials are located at various enterprises of the Rosatom State Corporation, mainly at the factories of the TVEL Fuel Company in the city of Novouralsk, Sverdlovsk Region – NPO “Centrotech” and Ural Electrochemical Plant. Moreover, there are additional areas on the Novouralsk site to create new production facilities in the future.

RusAT as an industry integrator will coordinate R&D of products, as well as provide a portfolio of orders and contracting. The strategic goal of the company is to provide revenues of up to 50 billion rubles by 2025 and occupy a share of more than 1.5% in the global AM market.

At this point, Rosatom has developed a prototype of a second-generation industrial 3D-printer. By the end of the year, it is planned to begin its mass production in Novouralsk. The cost of a domestic printer will be 20% lower than its foreign counterparts, and its characteristics will be higher.

Additive manufacturing have several advantages. First of all, this is a complex form of products that cannot be achieved by machining or casting, unique combinations of materials (for example, metal and ceramics), a significant reduction in the mass of the product and the swift prototype production. At the same time, products made with AM technology can be used in various fields, from nuclear and space technologies to medicine.