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Two ORNL researchers inspect carbon fiber materials - one black rectangular sheet and one see-through sheet of film.

Researchers at ORNL have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites – an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials. 

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. 

The seven entrepreneurs for Cohort 2024

Seven entrepreneurs comprise the next cohort of Innovation Crossroads, a DOE Lab-Embedded Entrepreneurship Program node based at ORNL. The program provides energy-related startup founders from across the nation with access to ORNL’s unique scientific resources and capabilities, as well as connect them with experts, mentors and networks to accelerate their efforts to take their world-changing ideas to the marketplace.

The 2023 Billion-Ton Report identifies feedstocks that could be available to produce biofuels to decarbonize the transportation and industrial sectors while potentially tripling the U.S. bioeconomy. The map indicates a mature market scenario, including emerging resources. Credit: ORNL/U.S. Dept. of Energy

The United States could triple its current bioeconomy by producing more than 1 billion tons per year of plant-based biomass for renewable fuels, while meeting projected demands for food, feed, fiber, conventional forest products and exports, according to the DOE’s latest Billion-Ton Report led by ORNL.

In a win for chemistry, inventors at ORNL have designed a closed-loop path for synthesizing an exceptionally tough carbon-fiber-reinforced polymer, or CFRP, and later recovering all of its starting materials.

In a win for chemistry, inventors at ORNL have designed a closed-loop path for synthesizing an exceptionally tough carbon-fiber-reinforced polymer, or CFRP, and later recovering all of its starting materials.

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.