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Manufacturing

Augmented reality for large-scale 3d printing
Augmented reality for large-scale manufacturing

Revolutionizing advanced manufacturing with the digital factory

A thriving manufacturing sector is vital to the nation’s economic health and global security, yet few companies possess the research and development capacity essential to staying competitive. Oak Ridge National Laboratory (ORNL) draws upon unmatched capabilities in materials, neutrons, and computational science to develop innovative manufacturing technologies, helping large and small companies alike. These efforts are directed toward solutions that will drive US economic competitiveness and energy productivity.

Using ORNL’s world-class resources for scientific discovery, such as Summit, the world’s fastest supercomputer, the Spallation Neutron Source (SNS), and the High Flux Isotope Reactor (HFIR), researchers can examine microstructures to better design new materials and fabrication methods, leverage multidisciplinary expertise for the development of new bio-based materials, and measure residual stress to certify printed components.

 

MedUSA, large-scale hybrid additive manufacturing system
"MedUSA," large-scale hybrid additive manufacturing platform

Next-Generation Manufacturing: The Digital Framework
 

ORNL is creating a digital framework suitable for a range of manufacturing technologies while integrating existing processes to provide new, optimized solutions.  This approach ensures that critical facilities and intellectual capital are accessible to industry while addressing US manufacturing challenges. ORNL is using unparalleled capabilities to advance next-generation energy-efficient manufacturing methods and systems. These capabilities include novel robotics, controls and automated systems; simulation, data analytics, visualization, artificial intelligence and machine learning.

 

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Research Areas

Bio-derived Materials for Additive Manufacturing

By integrating basic and early-stage applied energy capabilities, ORNL is leading the way to developing new bio-derived materials for a variety of applications using large-scale additive manufacturing.

High Performance Computing for Additive Manufacturing

ORNL is leading the Transforming Additive Manufacturing Through Exascale Simulation project (ExaAM), a project that uses supercomputing to improve additive manufacturing processes.

Creating Born-Certified Components

A number of software tools have been developed and shared with industry to improve the quality and performance of additive components. These tools are now being used to redefine how we design, build and qualify energy generation systems as well as aerospace and automotive components.

Hybrid Systems

ORNL is combining additive and subtractive capabilities in one system, creating a hybrid system with multiple advantages including cladding for multi and hybrid materials and embedded wireless sensors capable of in-situ monitoring.

Large-scale Infrastructure

ORNL is developing fieldable concrete deposition systems with pick and place capabilities allowing for full-scale automated construction of infrastructure for energy generation applications.

Large-scale thermoplastic and thermoset

ORNL is improving software, hardware and materials in large-scale thermoset and thermoplastic systems for 3D printing cellular core structures, tools and dies with increased z-strengths and low coefficients of thermal expansion. In addition to continuous