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From small beginnings to big creations: AES builds on ORNL's additive manufacturing insights

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Oak Ridge National Laboratory Manufacturing Demonstration Facility researchers have worked with AES for a decade to develop new 3D printing capabilities for large polymer prints. From left to right are Mark Johnson, DOE; Andrew Bader, AES; Austin Schmidt, AES; Brian Post, ORNL; Alex Roschli, ORNL; and John Lindahl, ORNL Credit: AES
Oak Ridge National Laboratory Manufacturing Demonstration Facility researchers have worked with AES for a decade to develop new 3D printing capabilities for large polymer prints. From left to right are Mark Johnson, DOE; Andrew Bader, AES; Austin Schmidt, AES; Brian Post, ORNL; Alex Roschli, ORNL; and John Lindahl, ORNL Credit: AES

Additive Engineering Solutions, or AES, an Ohio-based company, was forged to meet the growing demand for large polymer 3D prints in aerospace, defense and construction — a niche identified through pioneering research at the Department of Energy’s Manufacturing Demonstration Facility, or MDF, at Oak Ridge National Laboratory. Partners Austin Schmidt and Andrew Bader are driving additive manufacturing innovation and continuing collaboration with the MDF to elevate the capabilities of large-format 3D polymer printing.

Problem

While ORNL's MDF excels in researching and developing solutions for manufacturing challenges, it does not serve as a source of production components for industry. After collaborating on a large-format polymer print at the MDF, then-Caterpillar engineer Austin Schmidt found himself frustrated by the lack of companies able to fulfill his need for additional large-format 3D polymer prints.

Solution

To address this gap in the 3D-printing market, Schmidt and Andrew Bader launched AES. Positioned as a reliable source for large polymer prints using BAAM (big area additive manufacturing), AES continues to enhance its processes through direct collaboration with ORNL—particularly in refining the advanced functionalities of the Slicer software developed by ORNL.

Researchers at Oak Ridge National Laboratory's Manufacturing Demonstration Facility worked with Caterpillar, Inc. to develop this large 3D print of a mock-up for bulldozer assembly verification in 2016. Credit: AES
Researchers at Oak Ridge National Laboratory's Manufacturing Demonstration Facility worked with Caterpillar Inc. to develop this large 3D print of a mock-up for bulldozer assembly verification in 2016. Credit: ORNL, U.S. Dept. of Energy

Results

The establishment of AES has transformative implications for U.S. manufacturing, construction, and product distribution. Key outcomes include:

  • Scaling advanced manufacturing: In the early days of AES, demand for large-format 3D-printed parts was limited. However, through innovative software advancements and polymer experimentation, the AES-ORNL partnership has stimulated demand across multiple manufacturing sectors.
  • Leveraging expertise: MDF developed the large-format BAAM printer with industry partner Cincinnati Incorporated, and provided essential support for the AES founders. Continued collaboration with MDF experts ensures that AES will remain at the forefront of advancements in printer software.
  • Benefits of local manufacturing: By collaborating with other Ohio companies, AES strengthens regional manufacturing ties. Additionally, leveraging Ohio's skilled workforce—with its rich history of machining and manufacturing—enhances AES’s operational capabilities.

Insights

The success of ORNL’s partnerships with industry is rooted within the MDF ecosystem, drawing upon partnerships beyond the immediate engagement with a single partner. Development and adoption of transformational manufacturing innovations often requires solving multifaceted technical challenges through the engagement of various R&D experts and supply chain stakeholders. 

The success of the ORNL and AES partnership draws upon multiple elements of the MDF ecosystem and yields critical lessons for the manufacturing sector:

  • Place-based innovation is essential. Collaborations among Ohio companies, including AES and Cincinnati Inc., create a robust regional ecosystem in advanced manufacturing.
  • Collaboration drives impact. The MDF’s shared innovation infrastructure provides a collaborative environment and shared access to advanced manufacturing tools and expertise, enabling industries and researchers to work together and accelerate the adoption of new technologies. AES access to ORNL expertise and cutting-edge equipment transformed innovative ideas into tangible solutions through rigorous testing and application.
  • Technology transfer unlocks commercialization. ORNL’s guidance and testing protocols were instrumental in forming a new industry focused on fulfilling orders for large-format polymer printing. Through industry’s direct collaboration and co-location with MDF researchers, technology was transferred firsthand to partners.
  • Long-term partnerships build networks. The association with ORNL has unlocked numerous potential business collaborations for AES, amplifying its market presence.

This collaboration illustrates the transformative potential of strategic partnerships between national laboratories and industry players. Together, they reshape regional economies, drive innovation, and prepare the workforce to meet future challenges. 

Quick Facts 

  • The first large-format additive manufacturing 3D printer was developed in 2014 through a partnership between DOE’s MDF and Cincinnati Inc.
  • AES has now processed and collected data on over 100 different thermoplastic materials for large-format 3D printing.
  • AES says its large-format additive manufacturing process is 50% faster than traditional methods, enabling them to produce tools over 10 feet long and weighing more than 1,500 pounds in just one day.
  • Depending on the geometry, AES asserts their prints can be 10% to 40% less expensive to manufacture than conventional tooling, offering a cost-effective alternative through durable thermoplastics compared to traditional metals and other materials.

Contacts

The Manufacturing Demonstration Facility, supported by DOE’s Advanced Materials and Manufacturing Technologies Office, is a nationwide consortium of collaborators working with ORNL to innovate, inspire and catalyze the transformation of U.S. manufacturing. Partner with the MDF.

MDF is the model for the national laboratory system’s C4 Partnering Model, which seeks to increase cross-sector collaboration and rapid technology development, decreasing a technology’s time-to-market and enabling a strong regional manufacturing and commercialization ecosystem. Learn more about C4 partnering opportunities across the United States. — Leslie Mullen