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The core of a wind turbine blade by XZERES Corporation was produced at the MDF using Cincinnati Incorporated equipment for large-scale 3D printing with foam.

In the shifting landscape of global manufacturing, American ingenuity is once again giving U.S companies an edge with radical productivity improvements as a result of advanced materials and robotic systems developed at the Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory.

Veda Galigekere is leading Oak Ridge National Laboratory’s work on fast, efficient, wireless charging of electric vehicles.

Galigekere is principal investigator for the breakthrough work in fast, wireless charging of electric vehicles being performed at the National Transportation Research Center at Oak Ridge National Laboratory.

ORNL collaborator Hsiu-Wen Wang led the neutron scattering experiments at the Spallation Neutron Source to probe complex electrolyte solutions that challenge nuclear waste processing at Hanford and other sites. Credit: Genevieve Martin/Oak Ridge National Laboratory, U.S. Dept. of Energy.

Researchers at the Department of Energy’s Oak Ridge National Laboratory, Pacific Northwest National Laboratory and Washington State University teamed up to investigate the complex dynamics of low-water liquids that challenge nuclear waste processing at federal cleanup sites.

Scott Smith holding machined aluminum part

When Scott Smith looks at a machine tool, he thinks not about what the powerful equipment used to shape metal can do – he’s imagining what it could do with the right added parts and strategies. As ORNL’s leader for a newly formed group, Machining and Machine Tool Research, Smith will have the opportunity to do just that.

Alex Roschli in front of BAAM

Alex Roschli is no stranger to finding himself in unique situations. After all, the early career researcher in ORNL’s Manufacturing Systems Research group bears a last name that only 29 other people share in the United States, and he’s certain he’s the only Roschli (a moniker that hails from Switzerland) with the first name Alex.

The concrete parts are installed in a residential and commercial tower (above center and below) on the site of the Domino Sugar Factory along the waterfront in Brooklyn. Windows in the tower resemble sugar crystals. Image credit: Gate Precast

A residential and commercial tower under development in Brooklyn that is changing the New York City skyline has its roots in research at the Department of Energy’s Oak Ridge National Laboratory.

To develop complex materials with superior properties, Vera Bocharova uses diverse methods including broadband dielectric spectroscopy. Credit: Oak Ridge National Laboratory, U.S. Dept. of Energy; photographer Jason Richards

Vera Bocharova at the Department of Energy’s Oak Ridge National Laboratory investigates the structure and dynamics of soft materials—polymer nanocomposites, polymer electrolytes and biological macromolecules—to advance materials and technologies for energy, medicine and other applications.

ORNL will use state-of-the-art R&D tools at the Battery Manufacturing Facility to develop new methods for separating and reclaiming valuable materials from spent EV batteries.

The use of lithium-ion batteries has surged in recent years, starting with electronics and expanding into many applications, including the growing electric and hybrid vehicle industry. But the technologies to optimize recycling of these batteries have not kept pace.

CO2 release by mild heating of the BIG-bicarbonate solid. The released CO2 gas is trapped in the orange balloon, while the released water vapors are trapped by condensation in the ice-cooled U-shaped tube. Credit: Neil J. Williams and Erick Holguin.

Scientists at the Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a process that could remove CO2 from coal-burning power plant emissions in a way that is similar to how soda lime works in scuba diving rebreathers. Their research, published January 31 in...