Optimized fuel assembly channels and methods of creating the same

Fuel assemblies (100/200) include an outer channel (120/121) having a physical configuration optimized for a position of the fuel assembly (100/200) within a core of a nuclear reactor. The position of the fuel assembly (100/200) with respect to an employed control blade (45a) in the nuclear reactor determines if the outer channel (120/121) may be thickened, reinforced, and/or fabricated of Zircaloy-4 or similar distortion-resistant material, so as to reduce or prevent distortion of the channel (120/121) against the control blade (45a), or thinned so as to increase water volume and enhance reactivity in the assembly (100/200). Reactor cores having configured fuel assemblies (100/200) include fuel assemblies (100/200) having different outer channels (120/121). Methods include determining operational characteristics of the fuel assembly (100/200), including likelihood of being placed directly adjacent to an employed control blade (45a), and physically selecting or modifying the outer channel of the fuel assembly (100/200) based thereon.