Location: Hawthorne, California
 Industry: Advanced Energy / Additive Manufacturing
 Partners: Meltio | MatterHackers

Pioneering Clean Energy Through Innovative Manufacturing

Valar Atomics, based in Hawthorne, California, is on a mission to revolutionize clean energy production. The company is developing high-temperature gas core reactors that use heat from the reactor to decompose water through thermochemical cycles, generating hydrogen. That hydrogen can then be combined with carbon dioxide to produce sustainable synthetic hydrocarbon fuels — a potential breakthrough for energy independence and environmental impact.

To move at the speed of innovation, Valar realized they needed complete control over their prototyping and manufacturing processes. Building their own in-house manufacturing capability became a priority — and additive manufacturing was key to making that happen.

Introducing the Meltio M600

To meet the unique material and performance demands of their technology, Valar adopted the Meltio M600, a metal additive manufacturing system known for its precision, flexibility, and compact design.

“It’s a great machine. It’s very affordable,” said David Gamboa, Prototype and Fabrication Lead at Valar Atomics. “The footprint-to-build-volume ratio is excellent — we’re able to produce very large parts, even up to 100 kilograms, and it fits perfectly in our shop.”

The Meltio M600’s ability to work with materials like carbon steel, stainless steel, and Inconel gives Valar the freedom to experiment with high-performance alloys that can withstand the extreme temperatures of their reactor designs.

From Subtractive to Additive: Reducing Waste and Cost

Before integrating the M600, Valar relied heavily on traditional subtractive manufacturing — a process that often required machining large metal bars down to size. This method consumed both time and resources.

One of Valar’s key reactor components, known as the “Reducer”, perfectly illustrates the transformation. This part channels hot helium as it exits the reactor core, demanding both precision and high thermal resilience.

“We originally planned to machine the Reducer from a solid Inconel bar that cost around $8,000,” said Sean Stassi, Mechanical Engineer at Valar Atomics. “Instead, we printed it using the Meltio M600 with a single spool of Inconel — about $2,000 total, and we only used half the spool. The cost savings were immediate and significant.”

Beyond cost, additive manufacturing eliminated the long lead times and extensive tool wear associated with traditional methods. The Meltio system enabled Valar to print complex geometries directly, saving both material and machining time while accelerating design iteration cycles.

Reliable Performance Meets Local Support

While the M600 brought flexibility and cost efficiency, MatterHackers’ partnership made implementation seamless. As a local resource, MatterHackers provided not just the machine and materials, but also ongoing technical support and guidance.

“MatterHackers is local, and it’s really helpful having someone nearby who stocks materials and can send someone out if we need help — whether it’s firmware updates or machine servicing,” said Stassi.

With MatterHackers’ responsive support and Meltio’s reliable performance, Valar’s team could focus on what they do best — advancing nuclear and hydrogen-based energy systems — without being bogged down by manufacturing hurdles.

Building the Future of Clean Energy, In-House

By leveraging the Meltio M600 and MatterHackers’ expertise, Valar Atomics has successfully established a fully functional, multi-disciplinary manufacturing department in-house — covering electrical, welding, and mechanical engineering disciplines.

“We’re here to build reactors, not just play with manufacturing technologies,” Stassi added. “The Meltio just works — it’s a practical, dependable tool that lets us move fast.”

The integration of the Meltio M600, backed by MatterHackers’ support, has empowered Valar Atomics to prototype faster, reduce costs, and maintain control over the critical components that will power their next-generation reactors.

About Valar Atomics

Valar Atomics is an advanced energy company developing gas core reactor technologies aimed at producing clean hydrogen and synthetic fuels from renewable sources. By uniting innovation in nuclear engineering with modern manufacturing techniques, Valar aims to redefine what’s possible in sustainable energy production.

About MatterHackers

MatterHackers is one of the largest digital manufacturing retailers in the U.S., providing 3D printers, materials, and technical expertise to empower engineers, researchers, and innovators to bring their ideas to life.