Concept, production and validation of a 3D-printed coil frame for the UST_2 modular stellarator

• A construction method for stellarator modular coils is developed and validated.
• 3D printed truss structure filled and moulded with a material able to solidify.
• The structure capability for forces in small stellarators has been estimated.
• A light bare truss frame and a covered rigid double hull frame have been tested.

Geometric complexity of stellarators hampers a straightforward production of conceived optimised magnetic configurations. Integration of the engineering design with new fabrication methods may reduce the production cost and accelerate the production process. A fast cycle production of experimental fusion devices also might result in a faster advance in fusion plasma science. Several different stellarators could be used to test configurations for improved turbulent transport or to validate new divertor configurations. In this framework, and based on the results from the previously built UST_1 stellarator, the present work try to study and validate the feasibility of 3D printing methods (additive manufacturing) for small experimental stellarators. The paper summarises the engineering development, fabrication and validation of a coil frame test sector for the UST_2 stellarator. The definition of the Last Closed Flux Surface and winding surface for the test sector is based on an optimised quasi-isodynamic poloidal stellarator, modified for enhanced in-vessel remote handling manipulation and wide space for divertors. A Filled-sparse coil frame concept is developed to still keep low the cost in spite of the present expensive 3D printing materials and printers.