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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. 

The heartbeat Detector is pictured here, which is a black rectangular box with a heartbeat line and wording on the top to reflect its name

The Heartbeat Detector, developed at ORNL and licensed by Geovox Security Inc., detects hidden individuals in vehicles by measuring suspension vibrations. Now using a compact black box and cloud software, the system is more affordable and easier to use, while remaining the industry standard worldwide.

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.

Three people standing in a lab holding materials

ORNL, the Tennessee Valley Authority and the Tennessee Department of Economic and Community Development were recognized by the Federal Laboratory Consortium, or FLC, for their efforts to develop Tennessee as a national leader in fusion energy.

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 ORNL scientists are standing outside in front of a blue window with a plant in the top middle of the photo

ORNL's Gregorich and Syed Islam recently completed Cohort 19 of the Energy I-Corps program, an initiative of DOE’s Office of Technology Transitions that provides teams of researchers and industry mentors with an immersive two-month training.

The graphic shows the headshot of Nick Sokol, with text overlay saying "Innovations Crossroads Cohort 2024"

Nick Sokol founded Algaeo, a company that uses microalgae to produce organic fertilizers, offering a sustainable, cost-effective alternative to synthetic fertilizers. Supported by Oak Ridge National Laboratory's Innovation Crossroads program, Sokol is developing this technology to improve soil health, boost plant growth and support small-scale farmers.