The UK’s ambitious goal to switch on a prototype fusion power plant by 2040 has just cleared a major technical checkpoint, El.kz reports citing Interesting Engineering.
A new research powerhouse, dubbed DIADEM, has been launched to solve a problem that has long plagued the energy sector, specifically how to force “uncooperative” metals to work together under the most extreme conditions on Earth.
“DIADEM is initially focusing on solving one of the key challenges in the development of fusion technology – how to simultaneously process two fundamentally different materials – tungsten and copper – together, in order to manufacture the components that will be used in future fusion power plants,” explained the research team in a press release.
At the heart of a fusion reactor materials must survive intense magnetic fields and heat that mimics the center of the sun.
Engineers have long known that tungsten (which doesn’t melt easily) and copper (which moves heat away quickly) are the perfect duo for these environments.
However, they are a metallurgical nightmare to combine. Because their melting points and expansion rates are so different, they typically crack or pull apart when joined by traditional welding or casting.
“Traditional manufacturing methods are unable to combine the metals effectively, but emerging additive manufacturing techniques offer new opportunities,” added the team.
Enter “metamaterials”
The University of Nottingham’s Centre for Additive Manufacturing (CfAM) is bypassing traditional limits by using Multi-Metal Laser Powder Bed Fusion (MM-LPBF). Instead of trying to weld two blocks of metal together, they are 3D-printing them simultaneously from the ground up.
This “molecular blending” creates what researchers call metamaterials. By controlling the metal composition at a microscopic scale, DIADEM can create a smooth transition between tungsten and copper, eliminating the weak “seams” that usually lead to component failure.
“Joining two dissimilar metals has been a critical problem for the fusion sector, where the ability to blend two metals together is imperative for progress in this area,” said Professor Richard Hague, Director of CfAM.
“We are opening the door to a new generation of engineered materials,” he added, noting that while fusion is the immediate goal, this 3D-printed material science will eventually transform aerospace engines and high-tech medical implants.
Strategic roadmap to 2040
The project is more than just a lab experiment; it is a critical pillar for STEP (Spherical Tokamak for Energy Production), the UK’s flagship program to commercialize fusion.
The DIADEM partnership brings together the UK Atomic Energy Authority (UKAEA) with industrial titans like Rolls-Royce.
This initiative is backed by the EPSRC’s Adventurous Manufacturing programme, signaling a strategic shift toward high-risk, high-reward engineering.
The project aims to move fusion from a scientific theory to a “commercial reality” by creating parts that are more durable and energy-efficient than anything currently in existence.
With this task, the UK aims not just to power its own grid, but to become a global exporter of the specialized hardware required for the clean energy transition.