Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a method to directly fabricate customized cans for the powder metallurgy hot isostatic pressing (PM-HIP) process using additive manufacturing. Traditional PM-HIP can manufacturing involves multiple steps such as metal forming, machining, and welding, which can introduce defects and limit design freedom. The ORNL team employed various 3D printing technologies, including laser and arc-based methods, to produce cans with geometries that precisely match the final component, reducing material waste and shortening production cycles. After filling the printed cans with metal powder and vacuum sealing, HIP treatment yields large, dense metal parts with minimal internal defects. This approach offers a transformative solution for manufacturing large critical components such as hydro turbine parts and pressure vessels for next-generation nuclear reactors.