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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.

Naval Academy midshipmen look at tiny particle fuels while touring ORNL. Credit: Lena Shoemaker/ORNL, U.S. Dept. of Energy

Nuclear engineering students from the United States Military Academy and United States Naval Academy are working with researchers at ORNL to complete design concepts for a nuclear propulsion rocket to go to space in 2027 as part of the Defense Advanced Research Projects Agency DRACO program.

Seeing the difference Ac-225 could make to cancer patients made Raina Setzer want to come to ORNL to directly work with the isotope. Credit: Allison Peacock/ORNL, U.S. Dept. of Energy

Raina Setzer knows the work she does matters. That’s because she’s already seen it from the other side. Setzer, a radiochemical processing technician in Oak Ridge National Laboratory’s Isotope Processing and Manufacturing Division, joined the lab in June 2023.

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.

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In response to a renewed international interest in molten salt reactors, researchers from the Department of Energy’s Oak Ridge National Laboratory have developed a novel technique to visualize molten salt intrusion in graphite.

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.

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.

ORNL’s Fulvia Pilat and Karren More recently participated in the inaugural 2023 Nanotechnology Infrastructure Leaders Summit and Workshop at the White House, held Sept. 11–13. Credit: ORNL, U.S. Dept. of Energy

ORNL’s Fulvia Pilat and Karren More recently participated in the inaugural 2023 Nanotechnology Infrastructure Leaders Summit and Workshop at the White House.

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.