EVERETT, Wash. — In an industrial stretch of Everett is a boxy, windowless building called Ursa. Inside that building is a vault built from concrete blocks up to 5 feet thick with an additional layer of radiation-absorbing plastic. Within that vault is Polaris, a machine that could change the world.
Helion Energy is trying to replicate the physics that fuel the sun and the stars — hence the celestial naming theme — to provide nearly limitless power on earth through fusion reactions.
The company recently invited a small group of journalists to visit its headquarters and see Polaris, which is the seventh iteration of its fusion generator and the prototype for a commercial facility called Orion that broke ground this summer in Malaga in Central Washington.
Few people outside of Helion have been provided such access; photographs were not allowed.
“We run these systems right now at 100 million degrees, about 10 times the temperature of the sun, and compress them to high pressure… the same pressure as the bottom of the Marianas Trench,” said Helion CEO and co-founder David Kirtley, referencing the deepest part of the ocean.
Polaris and its vault occupy a relative small footprint inside of Ursa. The majority of the space is filled with 2,500 power units. They’re configured into 4-foot-by-4-foot pallets, lined up in rows and stacked seven high. The units are packed with capacitors that are charged from the grid to provide super high intensity pulses of electricity — 100 gigawatts of peak power — that create the temperatures and pressure needed for fusion reactions.
All of that energy is carried through miles and miles of coaxial cables filled with copper, aluminum and custom-metal alloys. End-to-end, the cables would stretch across Washington state and back again — roughly 720 miles. They flow in thick, black bundles from the pallets into the vault. They curl on the floor in giant heaps before connecting to the tubular-shaped, 60-foot-long Polaris generator.
The ultimate goal is for the generator to force lightweight ions to fuse, creating a super hot plasma that expands, pushing on a magnetic field that surrounds it. The energy created by that expansion is directly captured and carried back the capacitors to recharge them so the process can be repeated over and over again.
And the small amount of extra power that’s produced by fusion goes into the electrical grid for others to use — or at least that’s the plan for the future.
‘Worth being aggressive’
Helion is a contender in a global race to generate fusion power for a rapidly escalating demand for electricity, driven in part by data centers and AI. No one so far has been able to make and capture enough energy from fusion to commercialize the process, but dozens of companies — including three other competitors in the Pacific Northwest — are trying.
The company aims by 2028 to begin producing energy at the Malaga site, which Microsoft has agreed to purchase. If it hits this extremely ambitious target — and many are highly skeptical — it could be the world’s first company to do so.
“There is a level of risk, of being aggressive with program development, new technology and timelines,” Kirtley said. “But I think it’s worth it. Fusion is the same process that happens in the stars. It has the promise of very low cost electricity that’s clean and safe and base load and always on. And so it’s worth being aggressive.”
Some in the sector worry that Helion will miss the mark and cast doubt on a sector that is working hard to prove itself. At a June event, the head of R&D for fusion competitor Zap Energy questioned Helion’s deadline.
“I don’t see a commercial application in the next few years happening,” said Ben Levitt. “There is a lot of complicated science and engineering still to be discovered and to be applied.”
Others are willing to take the bet. Helion has raised more than $1 billion from investors that include SoftBank, Lightspeed Venture Partners and Sam Altman, who is OpenAI’s CEO and co-founder, as well as Helion’s longtime chair of its board of directors. The company is able to unlock an additional $1.8 billion if it hits Polaris milestones.
The generator has been operating since December, running all day, five days a week, creating fusion, Kirtley said.
Energy without ignition
Helion is highly cautious — some would say too cautious — in sharing details on its progress. Helion officials say they must hold their tech close to the vest as Chinese competitors have stolen pieces of their intellectual property; critics say the secrecy makes it difficult for the scientific community to verify their likelihood of success in a very risky, highly technical field.
In August, Kirtley shared an online post about Helion’s power-producing strategy, which upends the conventional approach.
Most efforts are trying to achieve ignition in their fusion generators, which is a condition where the reactions produce more power than is required for fusion to occur. This feat was first accomplished at a national lab in California in 2022 — but it still wasn’t enough energy that one could put electricity on the grid.
Helion is not aiming for ignition but rather for a system that is so efficient it can capture enough energy from fusion without reaching that state.
Kirtley compares the strategy for producing power to regenerative braking in electric vehicles. Simply put, an EV’s battery gets the car moving, and regenerative braking by the driver puts energy back into the battery to help it run longer. In the fusion generator, the capacitors provide that initial power, and the fusion reaction resupplies the energy and a little bit more.
“We can recover electricity at high efficiency,” Kirtley said. Compared to other commercial fusion approaches, “we require a lot less fusion. Fusion is the hard part. My goal, ironically, is to do the minimum amount of fusion that we can deliver a product to the customer and generate electricity.”
