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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.

Oak Ridge High School student is working on an 3D printing machine donated by UT-Battelle

UT-Battelle has contributed up to $475,000 for the purchase and installation of advanced manufacturing equipment to support a program at Tennessee’s Oak Ridge High School that gives students direct experience with the AI- and robotics-assisted workplace of the future. 

The heartbeat Detector is pictured here, which is a black rectangular box with a heartbeat line and wording on the top to reflect its name

The Heartbeat Detector, developed at ORNL and licensed by Geovox Security Inc., detects hidden individuals in vehicles by measuring suspension vibrations. Now using a compact black box and cloud software, the system is more affordable and easier to use, while remaining the industry standard worldwide.

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 Âé¶¹Ó°Òô 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. 

Group of 11 people, 9 standing and two sitting are posing for a photo in front of University of Oklahoma red and white backdrop with UO logo. The two in front are shaking hands

The University of Oklahoma and Oak Ridge National Laboratory, the Department of Energy’s largest multi-program science and energy laboratory, have entered a strategic collaboration to establish a cutting-edge additive manufacturing center. 

Close up photo of components for jet engines, fanned out in a spiral from the center

Inspired by a visit to ORNL’s Manufacturing Demonstration Facility, Jonaaron Jones launched a career in additive manufacturing that led to founding Volunteer Aerospace and now leading Beehive Industries’ external parts business. Through close collaboration with MDF, Jones has helped drive Âé¶¹Ó°Òô in defense, aviation and energy, while growing high-tech jobs and strengthening the U.S. manufacturing base.

Secretary Wright leans over red computer door, signing with silver sharpie as ORNL Director Stephen Streiffer looks on

During his first visit to Oak Ridge National Laboratory, Energy Secretary Chris Wright compared the urgency of the Lab’s World War II beginnings to today’s global race to lead in artificial intelligence, calling for a “Manhattan Project 2.â€

A picture containing indoor, equipment, control panel

A research partnership between two Department of Energy national laboratories has accelerated inspection of additively manufactured nuclear components, and the effort is now expanding to inspect nuclear fuels. 

Man is flying drone in hurricane aftermath, holding the controller

During Hurricanes Helene and Milton, ORNL deployed drone teams and the Mapster platform to gather and share geospatial data, aiding recovery and damage assessments. ORNL's EAGLE-I platform tracked utility outages, helping prioritize recovery efforts. Drone data will train machine learning models for faster damage detection in future disasters. 

Picture shows magnetic domains in uranium with a blue and orange organic shapes, similar to lava flowing through water, but in graphic form

The US focuses on nuclear nonproliferation, and ORNL plays a key role in this mission. The lab conducts advanced research in uranium science, materials analysis and nuclear forensics to detect illicit nuclear activities. Using cutting-edge tools and operational systems, ORNL supports global efforts to reduce nuclear threats by uncovering the history of nuclear materials and providing solutions for uranium removal.