Overcoming Mechanical and Economic Barriers in Alternative Fusion Reactor Designs: A Comprehensive Engineering Framework

Abstract

As classical magnetic confinement (Tokamak) systems face persistent scalingand latency challenges, alternative architectures such as Magnetized Target Fusion(MTF) using liquid metal pistons and Inertial Confinement Fusion (ICF) presentviable pathways to net-positive energy. However, these models encounter severemechanical fatigue, microsecond synchronization failures, prohibitive material costs,and supply chain bottlenecks in High-Temperature Superconductor (HTS) produc-tion. This paper proposes a comprehensive engineering and economic frameworkaddressing each barrier: (1) implementation of aerospace-grade titanium alloys (Ti-6Al-4V) for mechanical longevity, supported by quantitative fatigue-life comparisonsagainst industrial steel; (2) AI-driven predictive synchronization architecture withspecified latency budgets, sensor bandwidths, and machine learning model selection;(3) HTS tape production scaling analysis with cost-projection curves; and (4) a de-tailed Energy Return on Investment (EROI) model demonstrating that aggressiveinitial capital expenditure ($2–5 billion range) is recoverable within 7–12 years ofcommercial operation. We conclude that the barriers to commercial fusion are nolonger fundamentally scientific but engineering-economic, and that a self-sustainingfusion–space economic loop via Direct Fusion Drives and asteroid mining can amor-tize initial terrestrial investments.