Kinectrics and Burloak Technologies Advance Applications for Metal Additive Manufacturing to Provide a Broader Range of Supply Chain Options

Kinectrics and Burloak Technologies, two recognized leaders in Canada in their respective fields of nuclear lifecycle services and additive manufacturing , have demonstrated successful application of metal additive manufacturing (AM) for nuclear energy applications. Their partnership, which began in 2021, is focused on leveraging AM to provide fully tested, nuclear-grade components to address obsolescence in operational fleets and support emerging reactor technologies.

Their latest success involves the additive manufacturing of a hydraulic manifold, a complex, pressure-retaining high-grade steel component that was originally produced through conventional means. This part was designed and manufactured to meet the stringent mechanical and safety requirements of nuclear service environments, and to demonstrate a nuclear qualification path for Burloak’s metal AM process, marking a significant step toward the broader adoption of AM in the nuclear sector.

Obsolescence Meets Innovation

With many nuclear plants operating beyond their original design life and OEM supply chains diminishing, the challenge of component obsolescence is intensifying. Conventional manufacturing solutions often fall short due to unavailable tooling, long lead times, or insufficient documentation. Additive manufacturing offers a fundamentally different approach—digital, flexible, and capable of producing geometrically complex parts directly from CAD data with short turnaround times.

Burloak’s 3D printed hydraulic manifold shown on the left; the conventionally manufactured equivalent shown on the right.

“Additive manufacturing enables on-demand production of replacement parts that are otherwise impossible to source,” said Jason Ball, VP/GM of Burloak. “We’re not only solving for obsolescence — we’re working with Kinectrics to help develop the framework for using the Additive Manufacturing (AM) process in the Canadian nuclear industry while creating new engineering options that meet and often exceed the performance of legacy manufacturing processes.”

Technical Highlights of the Hydraulic Manifold Qualification

The hydraulic manifold was produced at Burloak’s AS9100 and ISO 9001-certified facility using high-strength stainless steel [17-4 PH] and a laser powder bed fusion (L-PBF) process. The part includes internal passageways optimized for flow performance, benefiting from the geometric freedom that AM provides. Post-processing steps that were performed using Burloak’s in-house capabilities included NADCAP-accredited heat treatment, 5-axis CNC machining, ISO 17025-accredited lab testing, and advanced metrology.

Burloak in-house capabilities leveraged for the manifold project included (from left to right): 1) Printing with the EOS M290 platform; 2) NADCAP heat treatment capabilities that include HIP; 3) ISO 17025 lab testing

Kinectrics conducted a demonstration of a nuclear-grade qualification program on the component, drawing the following conclusions:

Material and mechanical testing passed:

  • Material properties were compared against ASTM A564 Specification for Hot-Rolled Age-Hardened Stainless-Steel Bars
  • Material was heat treated to successfully meet desired mechanical properties
    • Material properties exceeded ASTM A564 for Type 630 in H1150 condition

Pressure test passed:

  • Testing setup similar to proof test for TSSA registration of pressure-boundary components
  • The manifold successfully pressure tested at 2,812 psig (1.25x design pressure) for 10 minutes, with no leaks observed

Non-destructive examination passed:

  • Microstructural features consistent in the X, Y, and Z build directions
  • Microstructure very similar to that of 17-4 PH solution annealed and aged bar stock material
  • Density measured at >99.9%, exceeding the porosity requirement

Traceability and documentation:

  • Full traceability was maintained from powder characterization to final inspection, in accordance with Nuclear Quality Requirements

“This program demonstrates that AM parts can be qualified for nuclear use when the process is controlled and validated to nuclear-grade standards,” said David Marttila, Senior Director of Nuclear Equipment Solutions at Kinectrics. “We’ve applied the same rigor we bring to traditionally manufactured components, ensuring that safety, performance, and traceability remain uncompromised.”

Building a Pathway to Regulatory and Utility Acceptance

A major focus of the Burloak-Kinectrics partnership is to establish a repeatable and regulator-ready process for introducing printed metal parts into service. The hydraulic manifold project serves as a documented reference model for AM component qualification—from design inputs through manufacturing, inspection, and final performance testing.

“We are leveraging our established aerospace accreditations to accelerate adoption of AM in the nuclear industry,” said Jason Ball.

Kinectrics is engaging with utilities, OEMs, and regulators to present findings and share lessons learned, with the goal of accelerating industry adoption of AM for both replacement and forward-fit components.

Supporting Current Fleets and Future Reactors

While the initial focus is on addressing high-obsolescence risk components in Canada’s CANDU fleet and other aging nuclear reactors, both companies see a clear role for AM in the development of Small Modular Reactors (SMRs) and advanced reactor designs. AM’s ability to reduce part count, optimize fluid dynamics, and enable rapid prototyping aligns with the performance, cost, and scalability goals of next-generation nuclear technologies.

“As AM becomes more integrated into reactor design thinking, we’ll be able to deliver components that are not only qualified, but better engineered for reliability, efficiency, and performance,” Marttila said. “The groundwork we’re laying now will directly support the nuclear industry’s long-term sustainability.”