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Creating energy the way the sun and stars do — through nuclear fusion — is one of the grand challenges facing science and technology. What’s easy for the sun and its billions of relatives turns out to be particularly difficult on Earth.

Experts at the Manufacturing Demonstration Facility worked with Magotteaux-Pulaski to develop a more durable composition and new 3D-printing process for abrasion-resistant materials. Credit: Magotteaux

For more than 100 years, Magotteaux has provided grinding materials and castings for the mining, cement and aggregates industries. The company, based in Belgium, began its international expansion in 1968. Its second international plant has been a critical part of the Pulaski, Tennessee, economy since 1972.

The Fuel Pellet Fueling Laboratory at ORNL is part of a suite of fusion energy R&D capabilities and provides test equipment and related diagnostics for carrying out experiments to develop pellet injectors for plasma fueling applications. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

ORNL will team up with six of eight companies that are advancing designs and research and development for fusion power plants with the mission to achieve a pilot-scale demonstration of fusion within a decade.

Phil Snyder

When virtually unlimited energy from fusion becomes a reality on Earth, Phil Snyder and his team will have had a hand in making it happen.

From left to right, Cortney Piper, executive director of the Tennessee Advanced Energy Business Council; Susan Hubbard, ORNL deputy for science and technology; Dan Miller, innovation Crossroads program lead; and Mike Paulus, ORNL director of technology transfer, attend the Innovation Crossroads Showcase at the Knoxville Chamber on Sept. 22. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

A crowd of investors and supporters turned out for last week’s Innovation Crossroads Showcase at the Knoxville Chamber as part of Innov865 Week. Sponsored by ORNL and the Tennessee Advanced Energy Business Council, the event celebrated deep-tech entrepreneurs and the Oak Ridge Corridor as a growing energy innovation hub for the nation.

ORNL fusion technology scientist Tim Bigelow, right, stands near the control console in ORNL’s  fusion control room with Matt Houde of Quaise Energy. Their partnership aims to tackle technical challenges with the Millimeter Wave Drilling System that Quaise has developed. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy.

Researchers in the geothermal energy industry are joining forces with fusion experts at ORNL to repurpose gyrotron technology, a tool used in fusion. Gyrotrons produce high-powered microwaves to heat up fusion plasmas.

ORNL’s Bruce Pint, left, and Marie Romedenne review experiment results. Credit: ORNL, U.S. Dept. of Energy

Practical fusion energy is not just a dream at ORNL. Experts in fusion and material science are working together to develop solutions that will make a fusion pilot plant — and ultimately carbon-free, abundant fusion electricity — possible.

A team of fusion scientists and engineers stand in front of ORNL’s Helium Flow Loop device. From back left to front right: Chris Crawford, Fayaz Rasheed, Joy Fan, Michael Morrow, Charles Kessel, Adam Carroll, and Cody Wiggins. Not pictured: Dennis Youchison and Monica Gehrig. Credit: Carlos Jones/ORNL.

To achieve practical energy from fusion, extreme heat from the fusion system “blanket” component must be extracted safely and efficiently. ORNL fusion experts are exploring how tiny 3D-printed obstacles placed inside the narrow pipes of a custom-made cooling system could be a solution for removing heat from the blanket.

ORNL fusion scientist Elijah Martin is working with TAE Technologies to demonstrate the feasibility of field-reversed configuration reactors, a possible alternative to the traditional tokamak-based devices. Credit: ORNL.

ORNL manages the Innovation Network for Fusion Energy Program, or INFUSE, with Princeton Plasma Physics Laboratory, to help the private sector find solutions to technical challenges that need to be resolved to make practical fusion energy a reality.

Associate Laboratory Director Kathy McCarthy heads the ORNL directorate that manages proto-MPEX, a linear plasma device that informs the development of the MPEX tool for study of fusion materials. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

From the helm of a one-of-a-kind organization that brings nuclear fusion and fission expertise together to pave the way to expanding carbon-free energy, Kathy McCarthy can trace the first step of her engineering career back to