Advanced Manufacturing Exhibit

Developing durable coatings to withstand fusion reactor conditions

Fusion reactors hold promise as a clean energy source, but their plasma-facing components must survive extreme conditions: high heat flux, continuous plasma exposure, and strong neutron radiation. Tungsten is one of the most suitable candidates, given its high melting point (3422 °C), thermal conductivity, and radiation resistance. Yet fabricating thick, defect-free tungsten coatings has been a long-standing challenge.

At A*STAR, researchers developed advanced coating technologies and material process science to overcome these barriers. By refining deposition parameters, they produced tungsten layers over 15 μm thick using physical vapour deposition. Tests confirmed strong adhesion, high density, and stability. The coatings remained intact after 120 hours of thermal cycling at 400 °C and showed no damage under high-energy laser exposure. This work demonstrates how deep R&D in materials science is enabling durable components for fusion energy systems. Singapore’s contribution through A*STAR strengthens the global pursuit of sustainable energy by addressing critical gaps in reactor materials.

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Instant 3D imaging for semiconductor manufacturing

Semiconductor manufacturing demands fast, reliable inspection of micro-scale features, yet traditional 3D microscopes rely on Z-scanning that slows inspection and increases mechanical complexity. The One-Shot 3D Microscope, developed by A*STAR and commercialised by JM VisTec, introduces a new optical solution. Its patented chromatic lens splits light into colours, each focused at a different depth.

From a single shot, the system reconstructs a full 3D profile instantly, eliminating the need for scanning. It is the only known system that delivers full-field, area-based 3D capture in one shot. The microscope achieves 3 μm accuracy with a depth range of up to 350 μm and is reconfigurable for different resolution and application needs. It is already being applied to wafer profiling, solder ball inspection, and inline metrology for semiconductor processes. This demonstrates how research in optics can be applied to strengthen capabilities in advanced semiconductor production.

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Predicting quality in 3D-printed metal parts   

Metal additive manufacturing (AM) allows complex parts to be produced on demand, but quality issues such as porosity, warping and inconsistent microstructures remain barriers to adoption.

The Additive Manufacturing Digital Twin (AM-DT), created by A*STAR, addresses these challenges. This physics-based software simulates the AM process at both powder and part scales, predicting defects, thermal history, microstructure, and mechanical properties before printing begins. By reducing trial-and-error, AM-DT lowers development costs and shortens the path from design to production-ready parts. AM-DT is currently deployed at the Additive Innovation Centre and piloted with industry users.

As a Singapore-developed solution rooted in A*STAR’s computational research, AM-DT demonstrates how advanced modelling, and simulation can be translated into practical tools that make additive manufacturing more predictable and reliable for industry.

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