A 3D printing technology is saving time and tax dollars while the Idaho Cleanup Project makes strides toward retrieving a by-product of used nuclear fuel recycling for disposal. June 9, 2026
Office of Environmental Management
June 9, 2026
Estimated Read Time min
Idaho Environmental Coalition mechanical engineer Jeremiah Voss, left, and print technician Timothy Egan examine a 3D-printed design update for a robotic system to support the Idaho Cleanup Project’s Calcine Disposition Project.
IDAHO FALLS, Idaho — A 3D printing technology is saving time and tax dollars while the Idaho Cleanup Project (ICP) makes strides toward retrieving a by-product of used nuclear fuel recycling for disposal.
Engineers applied the technology to develop the latest iteration of a robotic system critical to the U.S. Department of Energy's Office of Environmental Management mission to safely remove and dispose of 4,400 cubic meters of calcine waste from stainless steel storage bins not designed for material removal.
ICP’s integration of 3D printing and other advanced technologies at the Idaho National Laboratory Site highlights how innovation can drive both operational and cost efficiency in legacy waste cleanup efforts.
All calcine waste must be removed from the state for permanent disposal under an agreement with the State of Idaho. DOE had converted liquid, high-level radioactive waste into calcine until those operations ended in 2000. The waste was created during historic used nuclear fuel reprocessing runs at the Idaho Nuclear Technology and Engineering Center.
This robotic system will be used to weld access points to calcine bin sets housed inside a facility at the Idaho National Laboratory Site.
The engineers needed to safely and remotely weld access risers to the bins inside the Calcined Solids Storage Facilities and cut precise openings to extract the granular, solid waste from the bins. The robotic system is their solution.
The 3D printing has been central to the robotic system’s development, allowing engineers to create models and parts that improve precision and accelerate the design process at a fraction of the cost of traditional fabrication methods.
“This process allowed us to detect and address issues early, ensuring the final design was optimized before moving to full-scale production,” said Jeremiah Voss, mechanical engineer with ICP contractor Idaho Environmental Coalition.
The latest robotic system builds upon the success of earlier designs, with key improvements:
- A push-pull wire delivery system for consistent weld quality
- Enhanced adjustability for precise control of welding and cutting in challenging conditions
- Updated motors that simplify controls, improving integration
Use of 3D printing has enabled the team to swiftly address complex challenges, such as the lack of an existing access point for calcine waste retrieval in one of the six concrete vaults called bin sets.
“This technology is critical to enabling the retrieval process while protecting workers and the environment from hazardous materials,” Voss said.
The adaptability of the robotic system suggests potential for broader applications in waste retrieval and environmental initiatives.
-Contributor: Ryan Christensen
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