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Materials produced via additive manufacturing, or 3D printing, can experience significant residual stress, distortion and cracking, negatively impacting the manufacturing process.

An ORNL invention proposes using 3D printing to make conductors with space-filling thin-wall cross sections. Space-filling thin-wall profiles will maximize the conductor volume while restricting the path for eddy currents induction.

A Family of Integrated On-board Charger for Single and Dual Motor based Electric Vehicle Power Train
The invention aims to reduce the cost, weight and volume of existing on-board electric vehicle chargers by integrating power electronic converters of the chargers with the traction inverter.

Quantifying tool wear is historically challenging task due to variable human interpretation. This capture system will allow for an entire side and the complete end of the cutting tool to be analyzed.

New demands in electric vehicles have resulted in design changes for the power electronic components such as the capacitor to incur lower volume, higher operating temperatures, and dielectric properties (high dielectric permittivity and high electrical breakdown strengths).

A new, simpler power module and manifold design shows lower weight and volume, which allows higher power density compared with current state of the art.

Wind or hydro power are predominantly large-scale with giant generators to convert wind or water captured by turbines into electricity. But residential-sized wind turbines could generate power for a whole house.

There is a strong drive to improve the electrical performance of a power module for power electronics applications including transportation, buildings, renewables, and power delivery.

Complex protective casings and housings are necessary for many applications, including combustion chambers of gas turbines used in aerospace engines. Manufacturing these components from forging and/or casting as a whole is challenging, costly, and time-consuming.