Executive Summary

This project was created to design, build, and test a Foam Shell Flow Culling Station to automate the sorting and inspection of foam shell targets for inertial fusion energy (IFE) research at General Atomics, a leader in defense and energy innovation. This research is critical to expanding on the potential for efficiently harnessing fusion energy, a sustainable clean-energy alternative. Poly-alpha-methylstyrene (foam) shells, critical components in IFE, require precise tolerances in diameter, sphericity, wall thickness, and uniformity to ensure successful ignition under laser compression. With the growing demand for the production of IFE shells, it is necessary to automate the current manual inspection methods to save both time and money moving forward. 

The final system, designed for shells ranging from 3–6 mm, operated in a fully submerged fluid environment to preserve the delicate shells. It comprised three key components: a converger to align shells into a single-file flow, a sensor-camera module to detect and simulate photographing shells for quality assessment , and a diverter to sort shells into pass or fail reservoirs based on operator input–(AI camera assessment was left out of the scope of our project). The system achieved an inspection frequency of 1 shell per 15 seconds and ensured safe handling of the shells.

Prototype testing confirmed the system's ability to effectively inspect and sort the foam shells while addressing challenges such as flow consistency, sensor accuracy, and mechanical robustness. The design demonstrated scalability, cost-efficiency, and the potential for seamless integration into IFE facilities.

This automated culling station enhanced research capabilities, significantly increased inspection throughput and supported the advancement of IFE as a clean, sustainable energy source. The project underscores the importance of engineering innovation in addressing global energy challenges while fulfilling professional and ethical responsibilities to promote planet sustainability and societal well-being.