Manufacturing

  • ORNL logo placeholder for Volumetric Inspection Platform with Sparse View X-ray Images

    Volumetric Inspection Platform with Sparse View X-ray Images

    The invention is a platform for volumetric manufacturing inspection from sparse-view X-ray images. Unlike single-view 2D inspection, the invention produces 3D defect characterization and estimated material volume loss. Unlike conventional in-line CT, it uses only a small number of production radiography views. Key differentiators include view-dependent detector geometry in the physics model, uncertainty-aware reconstruction outputs,

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  • ORNL logo placeholder for Compounding and Reactive Processing of Elastomers

    Compounding and Reactive Processing of Elastomers

    We report a composition and associated protocol which entails mechanochemical processing of a rubber matrix and the subsequent reaction of the masticated feedstock with a new class of rubber additive. Robust polymer networks are formed from the reaction of commodity rubber with the crosslinker, without needing sulfur, organic peroxides, accelerators or activators that are usually

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  • A woman with wavy brown hair, wearing a lab coat, sits in front of a computer in a brightly lit laboratory. She's looking at the screen, which displays data or code. A microscope is visible to her left, slightly out of focus. Image from Envato.

    FLOVA: A Unified Microstructure-to-Performance Platform

    FLOVA is an automated materials-engineering framework that connects microstructure characterization with predicted material performance. The platform analyzes material images to measure features such as porosity, fiber orientation, fiber length, and spatial distribution, while addressing complex microstructures that can be difficult to evaluate consistently. By organizing these measurements with relevant manufacturing and material data, FLOVA supports

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  • ORNL logo placeholder for Autonomous Toolpath Planning

    Autonomous Toolpath Planning

    Using sensors mounted on the robot or calibrated within the robot coordinate frame, a point cloud is generated. Depending on the sensors used and number of scans needed to fully capture the part and workspace, multiple point clouds may need to be combined and/or filtered. The part of interest is segmented from the remainder of

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  • Al Sizing Line Integration featured image

    Al Sizing Line Integration

    This technology uses an AI/ML-based framework to improve industrial fiber sizing processes for composite manufacturing. Fiber sizing can be affected by inconsistent wetting, fiber twisting, and nonuniform coating deposition, resulting in variable composite quality and costly trial-and-error process development. By combining real-time sensing, imaging, and predictive modeling, the framework supports more consistent coating application and

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  • A New Family of Creep Resistant Fe-based Fcc+L12 Medium Entropy Alloys featured image

    A New Family of Creep Resistant Fe-based Fcc+L12 Medium Entropy Alloys

    This technology introduces a family of lower-cost, iron-based medium-entropy alloys for structural components exposed to elevated temperatures and sustained mechanical loads. The alloys address the need for materials that retain strength and dimensional stability while resisting creep-related deformation. A controlled multiphase microstructure provides a balanced combination of strength, ductility, creep resistance, and long-term microstructural stability

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  • Next-Generation Air Handling System featured image

    Next-Generation Air Handling System

    Buildings often struggle to maintain occupant comfort while managing indoor air quality, particularly when multiple contaminants and changing environmental conditions must be addressed simultaneously. This technology introduces an advanced air handling system that enhances environmental control by coordinating temperature, humidity, and indoor air quality within a single platform. The system improves building performance by helping

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  • Use of Mechanical Disturbances for Dish Drying featured image

    Use of Mechanical Disturbances for Dish Drying

    Household dishwashers often struggle to fully dry dishware, particularly plastic items, leaving residual moisture that can increase cycle times and reduce user satisfaction. This technology improves drying performance by using controlled mechanical disturbances to remove water from dish surfaces during the drying cycle. By reducing the amount of moisture that must be evaporated, the approach

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  • A Continuous Process for the Electrochemical Graphitization of Amorphous Carbon Particles featured image

    A Continuous Process for the Electrochemical Graphitization of Amorphous Carbon Particles

    A continuous manufacturing process converts amorphous carbon particles into graphitized carbon materials for advanced industrial applications. Traditional graphitization methods often rely on batch processing and energy-intensive thermal treatments that can limit throughput and scalability. This technology uses an electrochemical approach within a continuous reactor system to produce graphitized carbon particles more efficiently, enabling streamlined production

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  • Strengthening Adhesively Bonded Metal Joints featured image

    Strengthening Adhesively Bonded Metal Joints

    Structural adhesives are widely used across manufacturing industries, but achieving strong, durable bonds while maintaining ease of handling and storage remains a challenge. This technology improves adhesive performance through a novel approach to managing adhesive composition and surface interactions during processing. The result is stronger bonded metal joints, simplified application, and improved usability without compromising

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  • Dry Cryo-Processing for Solid State Battery Material Mixing featured image

    Dry Cryo-Processing for Solid State Battery Material Mixing

    Solid-state battery manufacturing can be limited by conventional material mixing approaches that may negatively affect material performance and processing efficiency. This technology uses a low-temperature dry-processing method to blend battery materials and binders without liquid-based manufacturing steps. The approach produces a more uniform material morphology while reducing the impact of binders on battery performance. The

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  • Method for Accurately Increasing the Softening Point of of Coal Tar Pitch featured image

    Method for Accurately Increasing the Softening Point of of Coal Tar Pitch

    A process for upgrading coal-derived liquids into higher-value isotropic coal tar pitch suitable for advanced carbon-based products. Many coal liquids and low-softening-point pitches are unsuitable for demanding industrial applications. The technology enables controlled enhancement of pitch properties, allowing a broader range of feedstocks to be converted into materials appropriate for carbon fiber, graphite, and electrode

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