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Technical illustration of an EV battery collector with vehicle placement shown in background.

Strengthening the competitiveness of the U.S. transportation industry depends on developing domestic EV batteries that combine rapid charging with long-range performance — two goals that often conflict. Researchers at ORNL have addressed this challenge by redesigning a key battery component, enabling fast, 10-minute charging while improving energy density and reducing reliance on copper.

Illustration of melting point of lithium chloride, which is shown with green and blue structures in two rows.

Scientists have developed a new machine learning approach that accurately predicted critical and difficult-to-compute properties of molten salts, materials with diverse nuclear energy applications. 

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 ORNL 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.

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. 

Two cylinders on each side of the photo are pointing to bright glowing orb in the center.

Scientists at ORNL have developed a method that can track chemical changes in molten salt in real time — helping to pave the way for the deployment of molten salt reactors for energy production.

Procter & Gamble scientists used ORNL’s Summit supercomputer to create a digital model of the corneal epithelium, the primary outer layer of cells covering the human eye, and test that model against a series of cleaning compounds in search of a gentler, more environmentally sustainable formula.

P&G is using simulations on the ORNL Summit supercomputer to study how surfactants in cleaners cause eye irritation. By modeling the corneal epithelium, P&G aims to develop safer, concentrated cleaning products that meet performance and safety standards while supporting sustainability goals.

Photo is a high aerial view of lake superior through the clouds

Researchers at Stanford University, the European Center for Medium-Range Weather Forecasts, or ECMWF, and ORNL used the lab’s Summit supercomputer to better understand atmospheric gravity waves, which influence significant weather patterns that are difficult to forecast. 

A silicon-carbide-based thermal protection system developed by ORNL and Sierra Space researchers will be used on the Sierra Space DC100 Dream Chaser.

Researchers with the Department of Energy’s Oak Ridge National Laboratory and Sierra Space Corporation have developed a new silicon-carbide-based thermal protection system, or TPS, for reusable commercial spacecraft. 

Pictured is a 3D printed roosting structure for bats.

Oak Ridge National Laboratory researchers are using a new bioderived material to 3D print custom roosting structures for endangered bats.

Pictured is a 3D printer that creates objects using electron beam melting, looks like a glowing orb.

Researchers have developed and 3D printed the lightest crack-free alloy capable of operating without melting at temperatures above 2,400 degrees Fahrenheit, which could enable additively manufactured turbine blades to better handle extreme temperatures, reducing the carbon footprint of gas turbine engines such as those used in airplanes.