Thorium-based fuel bundles according to one or more embodiments of the present invention provide a fresh fuel bundle comprising a first ring of fuel pins and a second ring of fuel pins. Each ring fuel pin has a fuel composition comprising uranium and thorium. The first ring fuel pins differ from the second ring fuel pins in each of the thorium wt %, uranium wt %, and .sup.235U enrichment.

Nuclear propulsion fission reactor structure has an active core region including fuel element structures, a reflector with rotatable neutron absorber structures (such as drum absorbers), and a core former conformal mating the outer surface of the fuel element structures to the reflector. Fuel element structures are arranged abutting nearest neighbor fuel element structures in a tri-pitch design. Cladding bodies defining coolant channels are inserted into and joined to lower and upper core plates to from a continuous structure that is a first portion of the containment structure. The body of the fuel element has a structure with a shape corresponding to a mathematically-based periodic solid, such as a triply periodic minimal surface (TPMS) in a gyroid structure. The nuclear propulsion fission reactor structure can be incorporated into a nuclear thermal propulsion engine for propulsion applications, such as space propulsion.

Nuclear propulsion fission reactor structure has an active core region including fuel element structures, a reflector with rotatable neutron absorber structures (such as drum absorbers), and a core former conformal mating the outer surface of the fuel element structures to the reflector. Fuel element structures are arranged abutting nearest neighbor fuel element structures in a tri-pitch design. Cladding bodies defining coolant channels are inserted into and joined to lower and upper core plates to from a continuous structure that is a first portion of the containment structure. The body of the fuel element has a structure with a shape corresponding to a mathematically-based periodic solid, such as a triply periodic minimal surface (TPMS) in a gyroid structure. The nuclear propulsion fission reactor structure can be incorporated into a nuclear thermal propulsion engine for propulsion applications, such as space propulsion.

Thorium-based fuel bundles according to one or more embodiments of the present invention are used in existing PHWR reactors (e.g., Indian 220 MWe PHWR, Indian 540 MWe PHWR, Indian 700 MWe PHWR, CANDU 300/600/900) in place of conventional uranium-based fuel bundles, with little or no modifications to the reactor. The fuel composition of such bundles is 60+ wt % thorium, with the balance of fuel provided by low-enriched uranium (LEU), which has been enriched to, according to one or more embodiments, 13-19.95% .sup.235U. According to various embodiments, the use of such thorium-based fuel bundles provides (1) 100% of the nominal power over the entire life cycle of the core, (2) high burnup, and (3) non-proliferative spent fuel bundles having a total isotopic uranium concentration of less than 12 wt %. Reprocessing of spent fuel bundles is also avoided.

A method of manufacturing a nuclear fuel segment includes varying a parameter of a lattice structure of a first mathematically-based periodic solid to form a second mathematically-based periodic solid. The second mathematically-based periodic solid comprises a triply periodic minimal surface (TPMS). The varying includes varying periodicity, thickness, or bias of the first mathematically-based periodic solid. The second mathematically-based periodic solid is embodied in a gridded mesh. The gridded mesh is sectioned into a plurality of layers. An additive manufacturing process is used to deposit a fissionable fuel composition in creating a body having a structure with a shape corresponding to the second mathematically-based periodic solid. The plurality of layers are used in controlling the additive manufacturing process.

A method for producing a fuel kernel is provided. The method comprises producing a dry fissile material comprising enriched uranium, forming a particle from the dry fissile material, the particle having a diameter of 1 millimeter or less; and thermally processing the particle to produce the fuel kernel. A press system for dry fissile material is also provided.