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By using computer-aided design and additive manufacturing, developers can improve the performance characteristics of geothermal tools, such as this optimized rotor design, and reduce production cost. Credit: ORNL/U.S. Dept. of Energy

Additive manufacturing can make the design and production of specialized tools for geothermal energy cheaper and more efficient, according to a study by Oak Ridge National Laboratory.

L-R: ORNL’s Omer Onar and Veda Galigekere with the dynamic wireless charging test bed at ORNL’s Grid Research Integration and Deployment Center. Credit: Carlos Jones, ORNL/U.S. Dept. of Energy

Consumer buy-in is key to the future of a decarbonized transportation sector in which electric vehicles largely replace today’s conventionally fueled cars and trucks.

ORNL, in collaboration with Cincinnati, Inc., used the Big Area Additive Manufacturing machine to 3D print a mold made of recycled thermoplastic composite and syntactic foam, demonstrating the potential for multimaterials in large-scale applications. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory researchers, in collaboration with Cincinnati Inc., demonstrated the potential for using multimaterials and recycled composites in large-scale applications by 3D printing a mold that replicated a single facet of a

Heavy-duty vehicles contribute 23% of transportation emissions of greenhouse gases and account for almost one-quarter of the fuel consumed annually in the U.S. Credit: Chris Bair/Unsplash

Through a consortium of Department of Energy national laboratories, ORNL scientists are applying their expertise to provide solutions that enable the commercialization of emission-free hydrogen fuel cell technology for heavy-duty

ORNL researchers used electron beam powder bed fusion to produce refractory metal molybdenum, which remained crack free and dense, proving its viability for additive manufacturing applications. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory scientists proved molybdenum titanium carbide, a refractory metal alloy that can withstand extreme temperature environments, can also be crack free and dense when produced with electron beam powder bed fusion. 

FAF5 diagram

A newly released dataset that tracks the movement of everything from food to gasoline across the United States by air, water, truck, rail and pipeline showed the value and tonnage of those goods rose significantly between 2012 and 2017.

ORNL researchers used an electrochemical process to heal dendrites that formed in a ceramic, garnet-based catalyst designed for a solid-state lithium battery. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

Scientists at Oak Ridge National Laboratory successfully demonstrated a technique to heal dendrites that formed in a solid electrolyte, resolving an issue that can hamper the performance of high energy-density, solid-state batteries.

ORNL researchers combined additive manufacturing with conventional compression molding to produce high-performance thermoplastic composites, demonstrating the potential for the use of large-scale multimaterial preforms to create molded composites. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory researchers combined additive manufacturing with conventional compression molding to produce high-performance thermoplastic composites reinforced with short carbon fibers.

ORNL researchers used gas metal arc welding additive technology to print the die for a B-pillar or vertical roof support structure for a sport utility vehicle, demonstrating a 20% improvement in the cooling rate. Credit: ORNL/U.S. Dept. of Energy

A team of Oak Ridge National Laboratory researchers demonstrated that an additively manufactured hot stamping die – a tool used to create car body components – cooled faster than those produced by conventional manufacturing methods.

ORNL researchers are developing a method to print low-cost, high-fidelity, customizable sensors for monitoring power grid equipment. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

A method developed at Oak Ridge National Laboratory to print high-fidelity, passive sensors for energy applications can reduce the cost of monitoring critical power grid assets.