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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 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 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. 

MedUSE wire-arc

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.

ORNL scientists used molecular dynamics simulations, exascale computing, lab testing and analysis to accelerate the development of an energy-saving method to produce nanocellulosic fibers.

A team led by scientists at ORNL identified and demonstrated a method to process a plant-based material called nanocellulose that reduced energy needs by a whopping 21%, using simulations on the lab’s supercomputers and follow-on analysis.

Jay Tiley inspects a hydroelectric runner from TVA’s Cherokee Dam

ORNL is working with industry partners to develop a technique that combines 3D printing and conventional machining to produce large metal parts for energy applications. The project, known as Rapid Research on Universal Near Net Shape Fabrication Strategies for Expedited Runner Systems, or Rapid RUNNERS, recently received $15 million in funding from DOE. 

This photo is of four men standing in front of a wall of monitors that are showing a tree looking image.

To better predict long-term flooding risk, scientists at the Department of Energy’s Oak Ridge National Laboratory developed a 3D modeling framework that captures the complex dynamics of water as it flows across the landscape. The framework seeks to provide valuable insights into which communities are most vulnerable as the climate changes, and was developed for a project that’s assessing climate risk and mitigation pathways for an urban area along the Southeast Texas coast.

People in a large convention room networking before a presentation

Vanderbilt University and ORNL announced a partnership to develop training, testing and evaluation methods that will accelerate the Department of Defense’s adoption of AI-based systems in operational environments.

This dataset, showing electricity outages from 2014-22 in the 50 U.S. states, Washington D.C. and Puerto Rico, details outages at 15-minute intervals for up to 92% of customers for the eight-year period.

ORNL researchers have produced the most comprehensive power outage dataset ever compiled for the United States. This dataset, showing electricity outages from 2014-22 in the 50 U.S. states, Washington D.C. and Puerto Rico, details outages at 15-minute intervals for up to 92% of customers for the eight-year period.

From left, Cable-Dunlap, Chi, Smith and Thornton have been named ORNL Corporate Fellows. Credit: ORNL, U.S. Dept. of Energy

Four researchers at the Department of Energy’s Oak Ridge National Laboratory have been named ORNL Corporate Fellows in recognition of significant career accomplishments and continued leadership in their scientific fields.

2023 Battelle Distinguished Inventors

Four scientists affiliated with ORNL were named Battelle Distinguished Inventors during the lab’s annual Innovation Awards on Dec. 1 in recognition of being granted 14 or more United States patents.