Skip to main content
Researchers found that moderate levels of ash — sometimes found as spheres in biomass — do not significantly affect the mechanical properties of biocomposites made up of corn stover, switchgrass and PLA thermoplastic. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

The presence of minerals called ash in plants makes little difference to the fitness of new naturally derived compound materials designed for additive manufacturing, an Oak Ridge National Laboratory-led team found.

Researchers at ORNL designed a recyclable carbon fiber material to promote low-carbon manufacturing. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory scientists designed a recyclable polymer for carbon-fiber composites to enable circular manufacturing of parts that boost energy efficiency in automotive, wind power and aerospace applications.

A new online tool developed by ORNL researchers, VERIFI, provides an easy to use dashboard for plant managers to track carbon emissions produced by industrial processes. The tool also monitors energy usage and produces trend reports. Credit: ORNL, U.S. Dept. of Energy

Researchers at ORNL have developed an online tool that offers industrial plants an easier way to track and download information about their energy footprint and carbon emissions.

Andrew Sutton joined ORNL in 2020 to guide a newly formed team that focuses on chemical process scale-up in advanced manufacturing. Credit: ORNL, U.S. Dept. of Energy

When Andrew Sutton arrived at ORNL in late 2020, he knew the move would be significant in more ways than just a change in location.

The students analyzed diatom images like this one to compare wild and genetically modified strains of these organisms. Credit: Alison Pawlicki/Oak Ridge National Laboratory, US Department of Energy.

Students often participate in internships and receive formal training in their chosen career fields during college, but some pursue professional development opportunities even earlier.

Shown here is a computer-aided design of the hot stamping die with visible cooling channels. Credit: Oak Ridge National Laboratory, U.S. Dept. of Energy

Researchers demonstrated that an additively manufactured hot stamping die can withstand up to 25,000 usage cycles, proving that this technique is a viable solution for production.

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.

The core of a wind turbine blade by XZERES Corporation was produced at the MDF using Cincinnati Incorporated equipment for large-scale 3D printing with foam.

In the shifting landscape of global manufacturing, American ingenuity is once again giving U.S companies an edge with radical productivity improvements as a result of advanced materials and robotic systems developed at the Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory.

Scott Smith holding machined aluminum part

When Scott Smith looks at a machine tool, he thinks not about what the powerful equipment used to shape metal can do – he’s imagining what it could do with the right added parts and strategies. As ORNL’s leader for a newly formed group, Machining and Machine Tool Research, Smith will have the opportunity to do just that.

Low-cost, compact, printed sensor that can collect and transmit data on electrical appliances for better load monitoring

Scientists at Oak Ridge National Laboratory have developed a low-cost, printed, flexible sensor that can wrap around power cables to precisely monitor electrical loads from household appliances to support grid operations.