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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. 

Illustration of the GRETA detector, a spherical array of metal cylinders. The detector is divided into two halves to show the inside of the machine. Both halves are attached to metal harnesses, displayed against a black and green cyber-themed background.

Analyzing massive datasets from nuclear physics experiments can take hours or days to process, but researchers are working to radically reduce that time to mere seconds using special software being developed at the Department of Energy’s Lawrence Berkeley and Oak Ridge national laboratories.  

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.

Illustration of a virtual meeting on a laptop screen featuring diverse cartoon avatars of people in a grid layout. In the center, a logo reads “Winter Classic Invitational Student Cluster Competition.” The background consists of digital blue circuitry and data flow patterns, suggesting a technology or computing theme.

ORNL researchers helped introduce college students to quantum computing for the first time during the 2025 Winter Classic Invitational, providing hands-on access to real quantum hardware and training future high-performance computing users through a unique challenge that bridged classical and quantum technologies.

INCITE

The Innovative and Novel Computational Impact on Theory and Experiment, or INCITE, program has announced the 2026 Call for Proposals, inviting researchers to apply for access to some of the world’s most powerful high-performance computing systems. 

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. 

Wall of black computer chords with blue wiring

Researchers from ORNL have developed a new application to increase efficiency in memory systems for high performance computing. Rather than allow data to bog down traditional memory systems in supercomputers and impact performance, the team from ORNL, along with researchers from the University of Tennessee, Knoxville, created a framework to manage data more efficiently with memory systems that employ more complex structures.