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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.

EERE Assistant Secretary Daniel Simmons, center right, with ORNL’s Xin Sun, EERE Deputy Assistant Secretary Alex Fitzsimmons and ORNL’s Moe Khaleel, helped launch new capabilities to advance connected and automated vehicle technologies at the DOE National Transportation Research Center at ORNL. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

ORNL and Department of Energy officials dedicated the launch of two clean energy research initiatives that focus on the recycling and recovery of advanced manufacturing materials and on connected and

Representatives from The University of Toledo and the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) in Tennessee are teaming up to conduct collaborative automotive materials research.” Credit: University of Toledo

ORNL and The University of Toledo have entered into a memorandum of understanding for collaborative research.

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.

Alex Johs at ORNL's Spallation Neutron Source

Sometimes solutions to the biggest problems can be found in the smallest details. The work of biochemist Alex Johs at Oak Ridge National Laboratory bears this out, as he focuses on understanding protein structures and molecular interactions to resolve complex global problems like the spread of mercury pollution in waterways and the food supply.

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Biologists from Oak Ridge National Laboratory and the Smithsonian Environmental Research Center have confirmed that microorganisms called methanogens can transform mercury into the neurotoxin methylmercury with varying efficiency across species.

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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.

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A team led by the Department of Energy’s Oak Ridge National Laboratory has identified a novel microbial process that can break down toxic methylmercury in the environment, a fundamental scientific discovery that could potentially reduce mercury toxicity levels and sup...