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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.

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.”

A picture containing indoor, equipment, control panel

A research partnership between two Department of Energy national laboratories has accelerated inspection of additively manufactured nuclear components, and the effort is now expanding to inspect nuclear fuels. 

Four scientists are standing in a field next to a data-gathering tool robot

Scientists at the Department of Energy’s Oak Ridge National Laboratory recently demonstrated an autonomous robotic field monitoring, sampling and data-gathering system that could accelerate understanding of interactions among plants, soil and the environment.

5 scientists in blue and white coats are leaning over the wind blades covered in orange and yellow material

ORNL researchers reached a significant milestone by building an entire 6.5-foot turbine blade tip using novel materials. The team then tested it against the forces of simulated lightning in a specialized lab at Mississippi State University, where the blade tip emerged pristine after tests that isolate the effects of high voltage. 

A speaker is standing at the podium in front of a PowerPoint slide with the title of the workshop on it, with 10 people in the audience

More than 200 stakeholders attended a recent workshop at DOE’s Manufacturing Demonstration Facility to discuss the future of powder metallurgy-hot isostatic pressing as a manufacturing technique.