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3D printed “Frankenstein design” collimator show the “scars” where the individual parts are joined

Scientists at ORNL have developed 3D-printed collimator techniques that can be used to custom design collimators that better filter out noise during different types of neutron scattering experiments

Images showing distortion caused by residual stress in the horizontal and vertical axes of material. ORNL researchers found that simply adding material in critical regions mitigates the accumulation of stress. Credit: ORNL, U.S. Dept. of Energy

ORNL scientists have determined how to avoid costly and potentially irreparable damage to large metallic parts fabricated through additive manufacturing, also known as 3D printing, that is caused by residual stress in the material. 

ORNL engineer Canan Karakaya uses computational modeling to design and improve chemical reactors and how they are operated to convert methane, carbon dioxide, ammonia or ethanol into higher-value chemicals or energy-dense fuels. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Canan Karakaya, a R&D Staff member in the Chemical Process Scale-Up group at ORNL, was inspired to become a chemical engineer after she experienced a magical transformation that turned ammonia gas into ammonium nitrate, turning a liquid into white flakes gently floating through the air. 

The 2023 Billion-Ton Report identifies feedstocks that could be available to produce biofuels to decarbonize the transportation and industrial sectors while potentially tripling the U.S. bioeconomy. The map indicates a mature market scenario, including emerging resources. Credit: ORNL/U.S. Dept. of Energy

The United States could triple its current bioeconomy by producing more than 1 billion tons per year of plant-based biomass for renewable fuels, while meeting projected demands for food, feed, fiber, conventional forest products and exports, according to the DOE’s latest Billion-Ton Report led by ORNL.

Wire arc additive manufacturing allowed this robot arm at ORNL to transform metal wire into a complete steam turbine blade like those used in power plants. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Researchers at ORNL became the first to 3D-print large rotating steam turbine blades for generating energy in power plants.

ORNL researchers contributed biomass resources analysis to a new report that says carbon dioxide removal targets can be reached by 2050 using existing technology. Source: Jason Richards/ORNL, U.S. Dept. of Energy

Scientists from more than a dozen institutions have completed a first-of-its-kind high-resolution assessment of carbon dioxide removal potential in the United States, charting a path to achieve a net-zero greenhouse gas economy by 2050.

2023 Battelle Distinguished Inventors

Four scientists affiliated with ORNL were named Battelle Distinguished Inventors during the lab’s annual Innovation Awards on Dec. 1 in recognition of being granted 14 or more United States patents.

SM2ART team members receive the CAMX Combined Strength Award at the Georgia World Congress Center in Atlanta. Pictured here are, from left, ORNL’s Dan Coughlin, Sana Elyas, Halil Tekinalp, Amber Hubbard, Soydan Ozcan; University of Maine’s Susan MacKay, Angelina Buzzelli, Scott Tomlinson, Wesley Bisson; and ORNL’s Matt Korey and Vlastimil Kunc. Credit: University of Maine

The Hub & Spoke Sustainable Materials & Manufacturing Alliance for Renewable Technologies, or SM2ART, program has been honored with the composites industry’s Combined Strength Award at the Composites and Advanced Materials Expo, or CAMX, 2023 in Atlanta. This distinction goes to the team that applies their knowledge, resources and talent to solve a problem by making the best use of composites materials.

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

3d prnited lunar rover wheel based on a NASA design

Researchers at the Department of Energy’s Oak Ridge National Laboratory, in collaboration with NASA, are taking additive manufacturing to the final frontier by 3D printing the same kind of wheel as the design used by NASA for its robotic lunar rover, demonstrating the technology for specialized parts needed for space exploration.