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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.

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.

Illustration of the GRETA detector, a spherical array of metal cylinders. The detector is divided into two halves to show the inside of the machine. Both halves are attached to metal harnesses, displayed against a black and green cyber-themed background.

Analyzing massive datasets from nuclear physics experiments can take hours or days to process, but researchers are working to radically reduce that time to mere seconds using special software being developed at the Department of Energy’s Lawrence Berkeley and Oak Ridge national laboratories.  

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.

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. 

Mengya Li is pictured here sitting at a computer in a lab.

Scientists at ORNL are studying the failure mechanisms of a new solid electrolyte battery to enhance long-term storage for renewable energy, aiming to make wind and solar power more reliable for the electric grid.

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.

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Researchers at ORNL are using advanced manufacturing techniques to revitalize the domestic production of very large metal parts that weigh at least 10,000 pounds each and are necessary for a variety of industries, including energy.