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Caption: Jaswinder Sharma makes battery coin cells with a lightweight current collector made of thin layers of aligned carbon fibers in a polymer with carbon nanotubes. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Electric vehicles can drive longer distances if their lithium-ion batteries deliver more energy in a lighter package. A prime weight-loss candidate is the current collector, a component that often adds 10% to the weight of a battery cell without contributing energy.

ORNL Composites Innovation staff members David Nuttall, left, and Vipin Kumar use additive manufacturing compression molding to produce a composite-based finished part in minutes. AMCM technology could accelerate decarbonization of the automobile and aerospace industries. Credit: ORNL, U.S. Dept. of Energy

Researchers at ORNL are extending the boundaries of composite-based materials used in additive manufacturing, or AM. ORNL is working with industrial partners who are exploring AM, also known as 3D printing, as a path to higher production levels and fewer supply chain interruptions.

The sun sets behind the ORNL Visitor Center in this aerial photo from April 2023. Credit: Kase Clapp/ORNL, U.S. Dept. of Energy

In fiscal year 2023 — Oct. 1–Sept. 30, 2023 — Oak Ridge National Laboratory was awarded more than $8 million in technology maturation funding through the Department of Energy’s Technology Commercialization Fund, or TCF.

Steven Campbell’s technical expertise supports integration of power electronics innovations from ORNL labs to the electrical grid. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Steven Campbell can often be found deep among tall cases of power electronics, hunkered in his oversized blue lab coat, with 1500 volts of electricity flowing above his head. When interrupted in his laboratory at ORNL, Campbell will usually smile and duck his head.

ORNL researcher Sreenivasa Jaldanki was recently elevated to IEEE senior member. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Sreenivasa Jaldanki, a researcher in the Grid Systems Modeling and Controls group at the Department of Energy’s Oak Ridge National Laboratory, was recently elevated to senior membership in the Institute of Electrical and Electronics Engineers, or IEEE.

Jonathan Harter, a technical professional in ORNL’s Engineering Science and Technology Directorate, uses a robot and other automated methods to disassemble electric vehicle batteries for recycling or reuse in the electric grid. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

After being stabilized in an ambulance as he struggled to breathe, Jonathan Harter hit a low point. It was 2020, he was very sick with COVID-19, and his job as a lab technician at ORNL was ending along with his research funding.

small power module

Researchers at the Department of Energy’s Oak Ridge National Laboratory are supporting the grid by improving its smallest building blocks: power modules that act as digital switches.

ORNL researchers encoded grid hardware operating data into a color band hidden inside photographs, video or artwork, as shown in this photo. The visual can then be transmitted to a utility’s control center for decoding. Credit: ORNL/U.S. Dept. of Energy

Inspired by one of the mysteries of human perception, an ORNL researcher invented a new way to hide sensitive electric grid information from cyberattack: within a constantly changing color palette.

Steven Campbell and Radha Krishna-Moorthy discuss part of the power electronics that make up the Smart Universal Power Electronics Regulator technology developed at ORNL. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Researchers at ORNL are helping modernize power management and enhance reliability in an increasingly complex electric grid.

This newly manufactured fixed guide vane of a hydropower turbine system was printed at the DOE Manufacturing Demonstration Facility at ORNL. Credit: Genevieve Martin/ORNL, U.S Dept. of Energy

A new report published by ORNL assessed how advanced manufacturing and materials, such as 3D printing and novel component coatings, could offer solutions to modernize the existing fleet and design new approaches to hydropower.