Mon, 02 February, 2026
We are pleased to announce that TWI is leading the ColdShield project, which aims to develop advanced radiation shielding materials and components tailored to specific reactor zones and operational requirements within the nuclear industry.
Although fusion energy promises a cleaner and more sustainable source of power, one of its key challenges is protecting sensitive reactor parts from intense neutron and gamma radiation. The ColdShield project will address this challenge by creating innovative shielding solutions using a cutting-edge manufacturing process called Cold Spray Additive Manufacturing (CSAM).
CSAM is a unique technology that sprays fine metal powders onto surfaces at supersonic velocities without melting them. This allows for the build-up large and complex components layer-by-layer while preserving the materials’ original properties.
By using CSAM, we can combine different materials with varying radiation shielding properties into a single, integrated component. This “graded-Z” shielding approach strategically places high-density materials to block gamma rays and lighter materials that absorb neutrons, potentially offering improved protection compared to traditional shielding methods.
The project will focus on selecting optimal materials, based on a multi-criterion framework, including high-fidelity neutronic simulations and testing, to ensure they can withstand the extreme conditions inside a fusion reactor, including high temperatures and radiation exposure. In the first phase, the project partners will develop small-scale prototypes to demonstrate the feasibility of this manufacturing technique for fusion shielding applications.
The project will draw upon our technical excellence in cold spray technology and take advantage of our state-of-the-art manufacturing facilities. We will work closely with fusion industry stakeholders to guide the project towards practical applications in next-generation fusion reactors such as STEP and DEMO.
ColdShield aims to produce shielding components that are not only more effective but also easier and more cost-efficient to manufacture and maintain. The technology could enable repairs and upgrades without replacing entire parts, helping to extend the lifespan of reactor components and reduce costs over time.
Ultimately, ColdShield supports the UK’s ambition to develop safe, reliable, and economically viable fusion energy by advancing key materials and manufacturing technologies essential for future fusion power plants.
This project is being funded by the United Kingdom Atomic Energy Authority (UKAEA), who have awarded contracts worth a total of £8.1 million to 14 organisations from its Fusion Industry Programme in order to develop shielding and fusion fuel technologies for future fusion power plants.