Italian Institute of Nuclear Physics uses 3D printing to advance science

The Italian National Institute of Nuclear Physics (INFN) has a strong reputation in the physics community and is known for its profound contributions to fundamental physics, especially the discovery of the Higgs boson and the verification of Einstein's gravitational waves. However, at Formnext 2024, INFN's booth showcased an innovation that is less well known to the general public: a groundbreaking application of 3D printing technology. As a research institution dedicated to revealing the mysteries of the universe, INFN has used additive manufacturing (AM) as an important tool in the process of promoting the development of science and technology, giving new impetus to scientific research.

First of all, INFN was founded in 1951 and is the cornerstone of Italian physics research, working closely with CERN and many universities around the world. The institution has four national laboratories in Italy and research departments in several cities, covering cutting-edge research in fields such as nuclear physics, particle physics and astrophysics. In an interview with 3DPrint.com, Pietro Rebesan, technical expert at INFN, pointed out that 3D printing has become an important means for INFN to promote innovation in scientific research. Rebesan said that additive manufacturing not only provides a convenient production method, but also can achieve complex designs and precision requirements that cannot be achieved by traditional manufacturing methods.

Secondly, INFN uses 3D printing extensively in the development of particle accelerators and related components, especially in the manufacture of customized parts that can withstand extreme conditions. These devices require components to be resistant to high temperatures, strong electromagnetic fields and high vacuum environments, and often use materials such as copper, niobium, and tantalum with excellent thermal, electrical, and mechanical properties. The advantages of 3D printing are its high precision and high efficiency, which can meet the manufacturing needs of these complex components and realize designs that cannot be completed by traditional manufacturing methods.

In addition, INFN is also exploring the use of 3D printing to promote nuclear fusion research. In the Development and Innovation of Additive Manufacturing (DIAM) group in Padua, INFN, RFX Alliance and University of Padua jointly applied for a patent for the design of the acceleration grid for the neutral beam injector. The grid design has complex geometry and intricate cooling channels, and 3D printing is its only manufacturing method. This design can not only improve the heat dissipation efficiency of the fusion process, but also reduce material stress, thereby enhancing the efficiency and reliability of fusion reactors.

Furthermore, materials science is one of the key pillars of INFN's additive manufacturing research. The institute focuses on developing high-performance materials for extreme environments, such as ultra-high temperatures and high vacuum conditions. INFN's laser powder bed fusion (LPBF) technology plays a key role in the production of small batches of high-cost alloy materials, especially niobium, tantalum, tungsten and other materials. Although most 3D printing and related processes are carried out in INFN's laboratories, INFN also cooperates with external companies, such as AMCM in Germany, for larger parts.

Although 3D printing has brought unprecedented innovation opportunities to scientific research, it still faces many challenges in practical applications. INFN researchers are constantly improving the surface treatment technology of 3D printed parts, especially the problem of powder residue removal in complex cooling channels. The improvement of post-processing technology is crucial to improving the quality and reliability of printed components.

Finally, in addition to its application in scientific research, INFN is also committed to translating its innovative technologies into practical applications. The institute cooperates with the industry through the Technology Transfer Office to bring research results to market, including patent licensing and co-developing customized solutions with enterprises. INFN's innovation is not limited to the field of physics, it has also promoted the birth of several spin-off companies.

In summary, INFN uses 3D printing technology to promote research in particle physics, nuclear physics, astrophysics and related fields, not only providing scientists with new research tools, but also bringing revolutionary applications to the industry. With the continuous development of 3D printing technology, INFN will undoubtedly play an increasingly important role in future scientific research and technological applications.