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3D printed “Frankenstein design” collimator show the “scars” where the individual parts are joined

Scientists at ORNL have developed 3D-printed collimator techniques that can be used to custom design collimators that better filter out noise during different types of neutron scattering experiments

Caption: Jaswinder Sharma makes battery coin cells with a lightweight current collector made of thin layers of aligned carbon fibers in a polymer with carbon nanotubes. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Electric vehicles can drive longer distances if their lithium-ion batteries deliver more energy in a lighter package. A prime weight-loss candidate is the current collector, a component that often adds 10% to the weight of a battery cell without contributing energy.

ORNL intern Jack Orebaugh holds the drone used in his research to help locate human remains. Credit: Lena Shoemaker/ORNL, U.S. Dept. of Energy

Jack Orebaugh, a forensic anthropology major at the University of Tennessee, Knoxville, has a big heart for families with missing loved ones. When someone disappears in an area of dense vegetation, search and recovery efforts can be difficult, especially when a missing person’s last location is unknown. Recognizing the agony of not knowing what happened to a family or friend, Orebaugh decided to use his internship at the Department of Energy’s Oak Ridge National Laboratory to find better ways to search for lost and deceased people using cameras and drones. 

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.

ORNL researchers are establishing a digital thread of data, algorithms and workflows to produce a continuously updated model of earth systems.

Digital twins are exactly what they sound like: virtual models of physical reality that continuously update to reflect changes in the real world.

 

A small droplet of water is suspended in midair via an electrostatic levitator that lifts charged particles using an electric field that counteracts gravity. Credit: Iowa State University/ORNL, U.S. Dept. of Energy

How do you get water to float in midair? With a WAND2, of course. But it’s hardly magic. In fact, it’s a scientific device used by scientists to study matter.

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.

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

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.