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A 3D printed thermal protection shield, produced by ORNL researchers for NASA, is part of a cargo spacecraft bound for the International Space Station. The shield was printed at the Department of Energy’s Manufacturing Demonstration Facility at ORNL. Credit: ORNL, U.S. Dept. of Energy

A research team at Oak Ridge National Laboratory have 3D printed a thermal protection shield, or TPS, for a capsule that will launch with the Cygnus cargo spacecraft as part of the supply mission to the International Space Station.

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

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.

self-healing elastomers
Researchers at Oak Ridge National Laboratory developed self-healing elastomers that demonstrated unprecedented adhesion strength and the ability to adhere to many surfaces, which could broaden their potential use
Colorized micrograph of lily pollen

Oak Ridge National Laboratory researchers have built a novel microscope that provides a “chemical lens” for viewing biological systems including cell membranes and biofilms.

Batteries - The 3D connection

Oak Ridge National Laboratory researchers have developed a thin film, highly conductive solid-state electrolyte made of a polymer and ceramic-based composite for lithium metal batteries.

Layering on the strength

A team including Oak Ridge National Laboratory and University of Tennessee researchers demonstrated a novel 3D printing approach called Z-pinning that can increase the material’s strength and toughness by more than three and a half times compared to conventional additive manufacturing processes.

Batteries—Polymers that bind

A team of researchers at Oak Ridge National Laboratory have demonstrated that designed synthetic polymers can serve as a high-performance binding material for next-generation lithium-ion batteries.

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Oak Ridge National Laboratory scientists studying fuel cells as a potential alternative to internal combustion engines used sophisticated electron microscopy to investigate the benefits of replacing high-cost platinum with a lower cost, carbon-nitrogen-manganese-based catalyst.

Manufacturing_tailoring_performance

A new manufacturing method created by Oak Ridge National Laboratory and Rice University combines 3D printing with traditional casting to produce damage-tolerant components composed of multiple materials. Composite components made by pouring an aluminum alloy over a printed steel lattice showed an order of magnitude greater damage tolerance than aluminum alone.