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Strengthening the competitiveness of the U.S. transportation industry depends on developing domestic EV batteries that combine rapid charging with long-range performance — two goals that often conflict. Researchers at ORNL have addressed this challenge by redesigning a key battery component, enabling fast, 10-minute charging while improving energy density and reducing reliance on copper.

Researchers at ORNL have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites – an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.

Recent advancements at ORNL show that 3D-printed metal molds offer a faster, more cost-effective and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.

Scientists at ORNL have developed a vacuum-assisted extrusion method that reduces internal porosity by up to 75% in large-scale 3D-printed polymer parts. This new technique addresses the critical issue of porosity in large-scale prints but also paves the way for stronger composites.
Scientists at ORNL have developed a method that can track chemical changes in molten salt in real time — helping to pave the way for the deployment of molten salt reactors for energy production.

Researchers with the Department of Energy’s Oak Ridge National Laboratory and Sierra Space Corporation have developed a new silicon-carbide-based thermal protection system, or TPS, for reusable commercial spacecraft.

Oak Ridge National Laboratory researchers are using a new bioderived material to 3D print custom roosting structures for endangered bats.

Researchers have developed and 3D printed the lightest crack-free alloy capable of operating without melting at temperatures above 2,400 degrees Fahrenheit, which could enable additively manufactured turbine blades to better handle extreme temperatures, reducing the carbon footprint of gas turbine engines such as those used in airplanes.

Researchers at ORNL are using advanced manufacturing techniques to revitalize the domestic production of very large metal parts that weigh at least 10,000 pounds each and are necessary for a variety of industries, including energy.

A study led by the Department of Energy’s Oak Ridge National Laboratory details how artificial intelligence researchers created an AI model to help identify new alloys used as shielding for housing fusion applications components in a nuclear reactor. The findings mark a major step towards improving nuclear fusion facilities.