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Using a toolpath strategy for weight reduction, two near-net shape dies were manufactured using a gas metal arc welding additive manufacturing process at the Lincoln Electric Additive Solutions facility. Credit: Lincoln Electric

Recent advancements at the U.S. Department of Energy’s Oak Ridge National Laboratory show that 3D-printed metal molds offer a faster, more cost-effective and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.

Oak Ridge High School student is working on an 3D printing machine donated by UT-Battelle

UT-Battelle has contributed up to $475,000 for the purchase and installation of advanced manufacturing equipment to support a program at Tennessee’s Oak Ridge High School that gives students direct experience with the AI- and robotics-assisted workplace of the future. 

A 3D printing nozzle wrapped in insulation extrudes black composite material into a small square mold on a green and white flat surface in a lab setting. Inset shows a close-up of a pressure gauge connected to brass valves and tubing.

Scientists at ORNL have developed a vacuum-assisted extrusion method that reduces internal porosity by up to 75% in large-scale 3D-printed polymer parts. This new technique addresses the critical issue of porosity in large-scale prints but also paves the way for stronger composites. 

ORNL researcher Jesse Labbe is working with plants in a greenhouse. He is framed on all sides with bright green leaves

Jesse Labbé aims to leverage biology, computation and engineering to address societal challenges related to energy, national security and health, while enhancing U.S. competitiveness. Labbé emphasizes the importance of translating groundbreaking research into practical applications that have real-world impact.

Group of 11 people, 9 standing and two sitting are posing for a photo in front of University of Oklahoma red and white backdrop with UO logo. The two in front are shaking hands

The University of Oklahoma and Oak Ridge National Laboratory, the Department of Energy’s largest multi-program science and energy laboratory, have entered a strategic collaboration to establish a cutting-edge additive manufacturing center. 

Close up photo of components for jet engines, fanned out in a spiral from the center

Inspired by a visit to ORNL’s Manufacturing Demonstration Facility, Jonaaron Jones launched a career in additive manufacturing that led to founding Volunteer Aerospace and now leading Beehive Industries’ external parts business. Through close collaboration with MDF, Jones has helped drive innovation in defense, aviation and energy, while growing high-tech jobs and strengthening the U.S. manufacturing base.

Erica Prates is presenting to a group of attendees at Vandy workshop in a table conference room, standing next to a screen glowing in white

Scientists at the Department of Energy’s Oak Ridge National Laboratory recently welcomed Vanderbilt University colleagues for a symposium on basic science research, with a focus on potential collaborations in the biomedical and biotechnology spaces.

Research scientist Daniel Jacobson is standing with his arms crossed with a dark black backdrop

Daniel Jacobson, distinguished research scientist in the Biosciences Division at ORNL, has been elected a Fellow of the American Institute for Medical and Biological Engineering, or AIMBE, for his achievements in computational biology. 

Different groups of proteins shown in different colors combine and attach to a broken strand of DNA.

Researchers at Georgia State University used the Summit supercomputer to study an elaborate molecular pathway called nucleotide excision repair. Decoding NER’s sophisticated sequence of events and the role of PInC in the pathway could provide key insights into developing novel treatments and preventing conditions that lead to premature aging and certain types of cancer.

Secretary Wright leans over red computer door, signing with silver sharpie as ORNL Director Stephen Streiffer looks on

During his first visit to Oak Ridge National Laboratory, Energy Secretary Chris Wright compared the urgency of the Lab’s World War II beginnings to today’s global race to lead in artificial intelligence, calling for a “Manhattan Project 2.”