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Caption: Jaswinder Sharma makes battery coin cells with a lightweight current collector made of thin layers of aligned carbon fibers in a polymer with carbon nanotubes. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Electric vehicles can drive longer distances if their lithium-ion batteries deliver more energy in a lighter package. A prime weight-loss candidate is the current collector, a component that often adds 10% to the weight of a battery cell without contributing energy.

An illustration shows how the composite is pressed into a seamless aluminum liner, which is then sealed with an aluminum powder cap. The research is sponsored by the DOE Isotope Program. Credit: Chris Orosco/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory researchers have developed a method to simplify one step of radioisotope production — and it’s faster and safer.

This newly manufactured fixed guide vane of a hydropower turbine system was printed at the DOE Manufacturing Demonstration Facility at ORNL. Credit: Genevieve Martin/ORNL, U.S Dept. of Energy

A new report published by ORNL assessed how advanced manufacturing and materials, such as 3D printing and novel component coatings, could offer solutions to modernize the existing fleet and design new approaches to hydropower.

Researchers at Oak Ridge National Laboratory developed an eco-friendly foam insulation for improved building efficiency. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Scientists at ORNL developed a competitive, eco-friendly alternative made without harmful blowing agents.

Researchers found that moderate levels of ash — sometimes found as spheres in biomass — do not significantly affect the mechanical properties of biocomposites made up of corn stover, switchgrass and PLA thermoplastic. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

The presence of minerals called ash in plants makes little difference to the fitness of new naturally derived compound materials designed for additive manufacturing, an Oak Ridge National Laboratory-led team found.

Technology to retrofit nonpowered dams such as the Lake Sequoyah Dam in North Carolina could be tested before deploying to ensure performance and reliability. Credit: Scott DeNeale/ORNL, U.S. Dept. of Energy

Researchers at Oak Ridge National Laboratory have identified a key need for future hydropower innovations – full-scale testing – to better inform developers and operators before making major investments.

Researchers at ORNL designed a recyclable carbon fiber material to promote low-carbon manufacturing. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory scientists designed a recyclable polymer for carbon-fiber composites to enable circular manufacturing of parts that boost energy efficiency in automotive, wind power and aerospace applications.

Melton Hill Dam

To further the potential benefits of the nation’s hydropower resources, researchers at Oak Ridge National Laboratory have developed and maintain a comprehensive water energy digital platform called HydroSource.

non-powered dam

Although more than 92,000 dams populate the country, the vast majority — about 89,000 — do not generate electricity through hydropower.

A large generator is installed at the Meldahl hydropower plant in Kentucky. The energy sector anticipates longer lead times in procuring such large components for increasing construction and modernization of U.S. hydropower plants. Credit: American Municipal Power

A new Department of Energy report produced by Oak Ridge National Laboratory identifies several supply chain must-haves in maintaining the pivotal role hydropower will play in decarbonizing the nation’s grid.