An advanced extruder, created through an ORNL-Strangpresse collaboration, powers the JuggerBot 3D printer. The technology supports prototyping for vehicles, aerospace, submarines and more. Credit: Amy Smotherman Burgess/ORNL, U.S. Dept. of Energy
When engineers at the Department of Energy’s Oak Ridge National Laboratory set out to improve industrial-scale 3D printing, they did more than solve a technical problem — they helped launch a company, support American manufacturing and accelerate innovation across multiple industries.
It began in 2013 when industrial-scale 3D printing was gaining momentum. ORNL was on the forefront with the development of the big area additive manufacturing, or BAAM, printer.
“BAAM revolutionized additive manufacturing because it printed orders of magnitude faster than anything on the market at that time,” said ORNL engineer Alex Roschli.
Most printers of that scale were using plastic welders as makeshift extruders, which is the part that deposits molten material during printing. Designed to fuse plastic sheets, not create complex shapes, this system led to slower processing times, material jams and reduced precision. ORNL and partner TW Womer addressed the issue with a custom-designed polymer extruder, increasing print speeds from 4 cubic inches per hour to 2,400.
“Not only is it faster, but you can also print more accurately,” said Roschli. “You can control the material flow precisely. It all comes back to making more reliable, efficient 3D printers.”
That breakthrough paved the way for a public-private partnership that underscores the unique role national laboratories play in driving industrial progress. By tackling tough technical challenges early and validating scalable solutions, ORNL helped reduce the risk for an industry partner that brought a new technology to the marketplace.
The success of BAAM and ORNL’s polymer extrusion work inspired the launch of Strangpresse, a startup focused on commercializing high-performance extruder technology. In 2017, ORNL licensed its extruder-related intellectual property to Strangpresse, which began developing a range of commercial products to address challenges in polymer extrusion for additive manufacturing.
“Obtaining an exclusive technology license from ORNL helped us secure a more competitive position for Strangpresse as we grew our company,” said Chuck George, the company’s chief executive officer.
ORNL engineers continued to innovate independently, developing software, control systems and hardware that improved performance. Key advancements include:
- The ORNL Slicer, custom slicing and toolpathing software tailored for large-scale printing
- A dual port nozzle, later licensed by Strangpresse, that automatically switches nozzle diameter mid-print to combine high- and low-resolution printing within the same build
- The tamper, or Z-leveler, which strengthens the printed part by pressing layers together, clears away excess material that can build up at the end of a print line and smooths the top surface, so the next layer prints more cleanly
The collaboration came full circle when ORNL acquired a JuggerBot 3D printer featuring the licensed Strangpresse extruder. ORNL now uses it for prototyping vehicles, boats and submarines and creating rapid, low-cost tooling for the automotive, marine, aerospace and construction industries.
The partnership exemplifies scientific innovation meeting commercial execution. ORNL and Strangpresse transformed an engineering challenge into a global solution with real-world impact.
To learn more about collaborating with ORNL, visit ornl.gov/partnerships.
The MDF, supported by Department of Energy’s Advanced Materials and Manufacturing Technologies Office, is a nationwide consortium of collaborators working with ORNL to innovate, inspire, and catalyze the transformation of U.S. manufacturing. Learn more about working with the MDF.
UT-Battelle manages ORNL for DOE’s Office of Science, the single largest supporter of basic research in the physical sciences in the United States. DOE’s Office of Science is working to address some of the most pressing challenges of our time. For more information, visit energy.gov/science. — Julya Johnson
