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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.

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.

Eric Nafziger, a technical staff member at the National Transportation Research Center at Oak Ridge National Laboratory’s Hardin Valley Campus, supports the installation of the largest alternative fuels research engines for marine and rail in the U.S. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Within the Department of Energy’s National Transportation Research Center at ORNL’s Hardin Valley Campus, scientists investigate engines designed to help the U.S. pivot to a clean mobility future.

ORNL’s Climate Change Science Institute and Georgia Tech co-hosted a Southeast Decarbonization Workshop in November 2023. Credit: ORNL, U.S. Dept. of Energy

ORNL's Climate Change Science Institute and the Georgia Institute of Technology hosted a Southeast Decarbonization Workshop in November that drew scientists and representatives from government, industry, non-profits and other organizations to 

Kim Tutin, founder and chief executive officer of Captis Aire, receives the EPA Green Chemistry Challenge Award. Credit: Eric Vance/USEPA

The founder of a startup company who is working with ORNL has won an Environmental Protection Agency Green Chemistry Challenge Award for a unique air pollution control technology. 

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.

Steve Nolan, left, who manages many ORNL facilities for United Cleanup Oak Ridge, and Carl Dukes worked closely together to accommodate bringing members of the public into the Oak Ridge Reservation to collect distant images from overhead for the BRIAR biometric recognition project. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Carl Dukes’ career as an adept communicator got off to a slow start: He was about 5 years old when he spoke for the first time. “I’ve been making up for lost time ever since,” joked Dukes, a technical professional at the Department of Energy’s Oak Ridge National Laboratory.