On August 26, 2026, Oak Ridge National Laboratory (ORNL) and Connecticut-based A.J. Tuck Company collaborated to produce leak-free capsules for hot isostatic pressing (HIP) by 3D printing a polymer mandrel, electroforming a 2–3 mm nickel shell around it, and then dissolving the mandrel with acid. The first five 6-inch × 4-inch cylindrical capsules were all leak-free, and an integrated port design eliminated the welded process tube—a common failure point. HIP capsules are critical containers for densifying metal powders under high temperature and pressure. This new approach reduces material strain and thermal distortion compared to metal AM capsule manufacturing, at lower cost, and a provisional patent has been filed. The second phase will target complex geometries such as impellers, with the goal of serving advanced U.S. nuclear reactors and small modular reactors—producing pressure vessels, valves, and pumps to replace overseas forged and cast supply chains. Growing demand for HIP forming is driving innovation in capsule manufacturing, and the electroforming route offers a lower-cost, leak-free sealing solution. Value to powder buyers: ① Lower HIP capsule costs will reduce overall post-processing costs for powder densification, supporting wider adoption of HIP services; ② U.S. localization policies for nuclear component supply chains create long-term scenarios for AM and powder demand; ③ Watch the indirect pull of electroformed capsule technology on the HIP market for titanium and nickel-based powders.