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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. 

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.

Troy Carter is standing on the staircase with a mural in the background showing the summit supercmputer

Troy Carter, director of the Fusion Energy Division at Oak Ridge National Laboratory, leads efforts to make fusion energy a reality, overseeing key projects like MPEX and fostering public-private collaborations in fusion research. 

Two men are talking on the backside of a semi trailer holding big wooden boxes

US ITER has completed delivery of all components for the support structure of the central solenoid, the 60-foot-tall superconducting magnet that is the “heart” of the ITER fusion machine. 

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.”

Two pictures of a rounded triangle shape are shown in mirror image. The left is white with red and purple spots in the middle while the one on the right is purple with a yellow and blue ring in the middle

Scientists designing the world’s first controlled nuclear fusion power plant, ITER, needed to solve the problem of runaway electrons, negatively charged particles in the soup of matter in the plasma within the tokamak, the magnetic bottle intended to contain the massive energy produced. Simulations performed on Summit, the 200-petaflop supercomputer at ORNL, could offer the first step toward a solution.

ORNL’s Askin Guler Yigitoglu presents during the 2024 Molten Salt Reactor Workshop in Knoxville with a green and blue background

ORNL’s annual workshop has become the premier forum for molten salt reactor, or MSR, collaboration and innovation, convening industry, academia and government experts to further advance MSR research and development. This year’s event attracted a record-breaking 365 participants from across the country, highlighting the momentum to bring MSRs online.