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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.

Researchers have shown how an all-solid lithium-based electrolyte material can be used to develop fast charging, long-range batteries for electric vehicles that are also safer than conventional designs. Credit: ORNL, U.S. Dept. of Energy

Currently, the biggest hurdle for electric vehicles, or EVs, is the development of advanced battery technology to extend driving range, safety and reliability.

ORNL’s additive manufacturing compression molding, or AMCM, technology can produce composite-based, lightweight finished parts for airplanes, drones or vehicles in minutes and could acclerate decarbonization for the automobile and aeropsace industries. 

An Oak Ridge National Laboratory-developed advanced manufacturing technology, AMCM, was recently licensed by Orbital Composites and enables the rapid production of composite-based components, which could accelerate the decarbonization of vehicles

Benefit breakdown, 3D printed vs. wood molds

Oak Ridge National Laboratory researchers have conducted a comprehensive life cycle, cost and carbon emissions analysis on 3D-printed molds for precast concrete and determined the method is economically beneficial compared to conventional wood molds.

ORNL researcher Zhijia Du inserts a newly developed liquid electrolyte material into a battery pouch cell. The formulation extends the life of extreme-fast-charging batteries like those used in electric vehicles. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory researchers are taking fast charging for electric vehicles, or EVs, to new extremes. A team of battery scientists recently developed a lithium-ion battery material that not only recharges 80% of its capacity in 10

ORNL researchers have developed a new pressing method, shown as blue circle on right, that produces a more uniform solid electrolyte than the traditionally processed material with more voids, shown as gray circle on left. The material can be integrated into a battery system, center, for improved stability and rate performance. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

ORNL scientists found that a small tweak created big performance improvements in a type of solid-state battery, a technology considered vital to broader electric vehicle adoption.

Neutron scattering experiments at the Spallation Neutron Source revealed how the dynamics between copper and oxygen make a special type of enzyme excel at breaking down biomass. Insights could lead to lowering the cost of biofuel production. Credit: Jill Hemman/ORNL, U.S. Dept. of Energy

Nonfood, plant-based biofuels have potential as a green alternative to fossil fuels, but the enzymes required for production are too inefficient and costly to produce. However, new research is shining a light on enzymes from fungi that could make biofuels economically viable.

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.

Researchers at Oak Ridge National Laboratory developed an eco-friendly foam insulation for improved building efficiency. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Scientists at ORNL developed a competitive, eco-friendly alternative made without harmful blowing agents.

Through the Honnold Foundation and Casa Pueblo, solar panels are installed in Adjuntas, Puerto Rico, and hooked to microgrids with battery storage. ORNL researchers are developing a microgrid orchestrator to manage the microgrids together for increased long-term electrical reliability. Credit: Fabio Andrade

ORNL researchers Ben Ollis and Max Ferrari will be in Adjuntas to join the March 18 festivities but also to hammer out more technical details of their contribution to the project: making the microgrids even more reliable.