The Five Barriers Fusion Must Still Overcome

On July 30th 2025, Helion Energy made history by officially beginning the construction of its first commercial fusion power facility in Malaga, Washington. Named Orion, the plant is designed to deliver electricity to the commercial grid. It became a monumental step that brings fusion energy closer to reality. 

This development is the culmination of years of dedicated research. Fusion energy, once seen as a mere dream, is now taking form in concrete and steel. What was once a scientific aspiration is now within reach.

However, this milestone is only one part of a long journey. The fusion energy development does not end with construction. Significant scientific, technical, and societal challenges remain before Helion or any fusion company can deliver reliable electricity to home and business.

So, what exactly stands between this new facility and the future  of clean energy?

1. Net Energy Gain: Turning Science into Power

Breakthroughs at facilities like the National Ignition Facility (NIF) have proven that fusion reactions can produce more energy than what’s put in to trigger them. The real challenge for commercial viability is achieving a net electricity gain where the total electricity generated by the plant is greater than the total electricity consumed to operate the entire facility. This includes powering the magnets that confine the plasma,  the heating system, and all other supporting infrastructure. This is one of the most technical hurdles in fusion energy science, but also the most important thing.

Helion uses a unique approach that involves fusion energy conversion into electricity, using a different approach as the one used in NIF, in 2024 Helion’s Polaris prototype has approached break-even conditions, they still need to maintain the consistency and scaling that up into usable electricity.

This step is really important for other companies because without net energy gain, the plant can’t generate actual electricity and fusion will remain as a scientific curiosity not a power solution.

2. Material and Engineering

Fusion can’t scale if its machine constantly breaks down or relies on rare fragile components. The interior of a fusion reactor is one of the harshest environments imaginable, with temperature exceeding 100 million degrees celsius. It requires high quality materials  and this became the biggest engineering challenge to develop materials that are strong and durable enough to both contain the superheated plasma and withstand the intense neutron radiation produced by the fusion reaction.  

While  the fusion supply chain is improving, the material used in reactor construction must be tested for long-term durability. There is still work to be done to ensure these materials can be mass-produced and maintained to support the ongoing operations. 

3. Regulation and Permitting

Fusion won’t go mainstream until legal and regulatory systems are in place to support it. Even though fusion has been a discussion for a decade, it’s still considered as a relatively new technology. There  is no universal, fully established framework for its permitting, safety, or commercial integration. 

While the U.S Nuclear Regulatory Commission  (NRC) has begun outlining a path forward for fusion (distinct from traditional nuclear fission), manny details remain unresolved. Pricing mechanisms for grid integration are also unclear. 

Fusion companies like Helion need to work closely with the governments and regulators to develop standards that ensure safety, accountability, and fairness without stalling innovation.

4, Commercial Viability

Despite a surge in private investment in the fusion industry, building and operating these power plants remains incredibly expensive. Companies must  prove that  their technology is not only technically feasible but also financially viable. They need to make sure that the cost of construction and the operation can compete with the other energy sources. Even though fusion have a great potential, without a financial support it would be as great that’s why it’s a crucial step to be watch for commercialization consideration

5. Public Perception and Political Support

One of the most important things for fusion  commercialization is the public  reception. No energy revolution happens without the support of people and policy makers. Without them, there’ll be no fusion in the market. For decades, fusion has been advertised as a clean and safest source of energy compared to nuclear fission.  That reputation is beginning to catch on,  but it takes time to build trust. Misunderstanding still exists, and many people confuse fusion with the risk of nuclear fission.

The discussion around fusion has already made people aware about it but there’ll still be more effort to build public confidence and political momentum. Without their support, future fusion projects may face resistance, even when their environmental benefits are clear. 

The Future of Fusion

Helion’s  fusion power  plant  is more than just a scientific breakthrough, it’s a sign that fusion is  really  moving into  the real  world. The transition wont be easy, fusion companies will face growing pressure to deliver results, prove reliability, and earn trust in this commercialization race.  What's going to happen in the next few years is going to define whether fusion becomes the cornerstone of a clean energy future or just remains  as a scientific achievement.