The University of Rochester’s Laboratory for Laser Energetics (LLE) is advancing a manufacturing process to address a critical bottleneck for commercial inertial fusion energy (IFE): the high-volume, low-cost production of fusion targets. An IFE power plant is projected to require approximately 10 targets per second, translating to nearly one million targets daily. Current fabrication methods, which are sufficient for experimental campaigns, produce only a few targets per day at a cost estimated in the hundreds of thousands of dollars each. LLE’s research aims to reduce this cost to about 25 cents per target, a price point deemed necessary for the economic viability of a future IFE power plant. This effort is fundamental to establishing the robust supply chain required for commercial fusion. Source: Ans

LLE's approach utilizes a fluidic system to generate the spherical shells that form the core of the fusion targets. Subsequent steps involve applying specialized coatings to these shells. While the laboratory has successfully produced thousands of targets for its own OMEGA laser system and for experiments at Lawrence Livermore National Laboratory’s National Ignition Facility, the current process is not scalable for commercial power generation. The primary challenge lies in transitioning from a bespoke, lab-scale fabrication technique to a continuous, automated manufacturing line capable of meeting the demanding repetition rates of an IFE plant. This involves significant research and development in materials science, precision engineering, and process control to ensure each of the millions of daily targets meets exacting specifications. Source: Ans

LLE's approach utilizes a fluidic system to generate the spherical shells that form the core of the fusion targets.

The economic case for inertial fusion energy hinges directly on solving this manufacturing problem. The cost of the target is a significant component of the projected levelized cost of electricity for an IFE system. The vast difference between current and required costs underscores the scale of the engineering challenge. Achieving the target price of 25 cents per unit necessitates a complete paradigm shift from manual assembly to industrial automation. This effort is part of a broader push within the private fusion sector to de-risk key enabling technologies beyond plasma physics, including fuel cycle management, materials, and power conversion systems, which are all essential for a commercially deployable fusion reactor. Source: Ans

As one of three inertial confinement fusion (ICF) programs in the United States supported by the National Nuclear Security Administration (NNSA), LLE is uniquely positioned to pursue this research. Its work complements the ignition-level physics experiments conducted at LLNL by focusing on the practical engineering required for a power plant. The development of a viable target supply chain is a long-lead-time item that must be addressed in parallel with ongoing physics research and reactor design. Progress in this area will be a key indicator of the maturation of IFE as a potential energy source, moving the concept from scientific demonstration toward industrial reality. Future work will focus on scaling up the fluidic system and automating the coating and quality control processes. Source: Ans