Fusion Reactor Vessel
A Large, Complex Vessel With Nuclear-Grade Weld Requirements
The vessel would operate below one atmosphere (8.1 psi) and was technically non-code—but the weld quality needed to be at the level of a nuclear system.
The Finished Product
Fusion Reactor Vessel
A Large, Complex Vessel With Nuclear-Grade Weld Requirements
The vessel would operate below one atmosphere (8.1 psi) and was technically non-code—but the weld quality needed to be at the level of a nuclear system.
HOW WE MADE IT HAPPEN
In the fast-paced world of new product development, resources and time are often limited. To overcome these challenges, companies can turn to APE for expert assistance to accelerate their development processes. This case study highlights how APE supported a military vehicle manufacturer in meeting critical delivery deadlines by developing an efficient weld fixturing system and manufacturing process.
As the military vehicle manufacturer approached the final stages of designing their latest vehicle, they faced a significant hurdle. They lacked both the in-house expertise and the bandwidth to develop the necessary fixturing system and manufacturing process to meet their delivery requirements. Recognizing the urgency, they reached out to APE for a solution.
APE’s expertise in developing advanced weld fixtures exemplifies how strategic partnerships can enhance a company’s capabilities and accelerate product development. This collaboration underscores APE’s commitment to providing solutions that meet the most demanding industry standards and delivery requirements.
Contact us today to learn how APE can help accelerate your product development process.
The Finished Product
Fusion Reactor Vessel
A Large, Complex Vessel With Nuclear-Grade Weld Requirements
The vessel would operate below one atmosphere (8.1 psi) and was technically non-code—but the weld quality needed to be at the level of a nuclear system.
The Finished Product
HOW WE MADE
IT HAPPEN
The Problem: A Large, Complex Vessel With Nuclear-Grade Weld Requirements
The vessel would operate below one atmosphere (8.1 psi) and was technically non-code—but the weld quality needed to be at the level of a nuclear system. The challenges stacked up quickly:
- Welds required ±0.015" fit-up tolerance
- Large-diameter cylindrical structure requiring precision rotation
- No time for redesign cycles or trial builds
- A timeline that demanded seven-day workflow coordination
If they couldn’t get an engineered, code-quality vessel on schedule, key fusion testing milestones would slip.
Why They Turned to APE
The client’s procurement manager had worked with APE before and understood what was at stake. He chose APE because he knew the team could serve as a guide, not just a fabricator—one capable of:
- Completing mechanical engineering and DFM refinement quickly
- Managing the entire build with clear, proactive communication
- Executing nuclear-grade welds on a massive stainless structure
- Delivering under a deadline that required weekend shifts and zero rework
By handing off the mechanical design and manufacturing to APE, the client’s engineers stayed focused on system development instead of getting buried in fabrication details.
APE’s Plan: Engineering Clarity → Precision Fabrication → Confident Delivery
To keep the client’s reactor program on schedule, APE established a clear, executable path:
- Engineering & DFM Ownership
APE finalized the design, optimized weld prep, and verified manufacturability before fabrication began.
- Precision Welding Setup
The vessel was mounted on tank rollers so welders could maintain ideal torch position, consistent penetration, and perfect bead geometry across long seams.
- ±0.015" Fit-Up Across All Joints
Each weld prep was machined and aligned to tight tolerances that ensured structural integrity and consistent penetration.
- Certified Inspection at Every Step
Every weld was visually inspected and dye-penetrant tested by certified inspectors—often on nights and weekends—to stay ahead of schedule.
- Rigging & Transport Engineering
APE designed lifting lugs, blocking, and rotation plans to safely transition the vessel from horizontal fabrication to vertical installation onsite.
- Custom Shipping Stands
Fabricated to protect the vessel during transport and streamline staging at the fusion site.
The Outcome: A Mission-Critical Fusion Vessel Delivered on Schedule
Despite the scale, complexity, and aggressive timeline, APE delivered the vessel on time and to spec—allowing the client’s fusion research program to move forward exactly as planned.
Deliverables included:
- A stainless steel filtration vessel with nuclear-grade weld quality
- Certified inspection documentation for every weld
- Engineered rigging, lugs, and packaging systems
- A design refined through DFM for future builds
For fusion innovators operating on the edge of scientific and engineering possibility, the difference between momentum and delay often comes down to manufacturing execution. APE ensured their momentum never slowed.
The Bigger Picture
This project demonstrates APE’s role as a trusted partner for advanced energy and high-technology companies:
We help innovators turn early concepts into real, test-ready hardware—fast, accurate, and engineered for what comes next.
Whether it’s nuclear systems, aerospace structures, or advanced robotics, APE blends DFM expertise with world-class fabrication to reduce risk and accelerate development.
Ready to Build What’s Next?
If you’re developing fusion systems, advanced energy equipment, or precision mechanical assemblies, APE provides design-through-fabrication support for industries where failure is not an option.
Let’s bring the future closer. Contact us to discuss your next project.
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