Revolutionizing advanced manufacturing with the digital factory
ORNL develops next-generation manufacturing technologies that strengthen U.S. industry through advanced materials, automation, and world-class scientific capabilities.
A thriving manufacturing sector is vital to the nation’s economic health and global security, yet few companies possess the research and development (R&D) capacity essential to staying competitive. Oak Ridge National Laboratory (ORNL) draws upon unmatched capabilities in materials, neutrons, and computational science to develop innovative manufacturing technologies, helping large and small companies alike. These efforts are directed toward solutions that will drive US economic competitiveness and energy productivity.
Using ORNL’s world-class resources for scientific discovery, such as Summit, the world’s fastest supercomputer, the Spallation Neutron Source (SNS), and the High Flux Isotope Reactor (HFIR), researchers can examine microstructures to better design new materials and fabrication methods, leverage multidisciplinary expertise for the development of new bio-based materials, and measure residual stress to certify printed components.
Next-Generation Manufacturing: The Digital Framework
ORNL is creating a digital framework suitable for a range of manufacturing technologies while integrating existing processes to provide new, optimized solutions. This approach ensures that critical facilities and intellectual capital are accessible to industry while addressing US manufacturing challenges. ORNL is using unparalleled capabilities to advance next-generation energy-efficient manufacturing methods and systems. These capabilities include novel robotics, controls and automated systems; simulation, data analytics, visualization, artificial intelligence and machine learning.
Unique Facilities
Manufacturing Demonstration Facility
The nation’s only large-scale open-access facility for rapidly demonstrating early stage R&D manufacturing technologies and optimizing critical processes.
Carbon Fiber Technology Facility
Developing methods using low-cost feedstocks to assist industry in overcoming the barriers of carbon fiber production cost, scalability of processes, and development of fiber-reinforced polymer composites for end use.
Battery Manufacturing Facility
The country’s largest open-access battery and research development center focused on high-performance, low-cost water-borne processing technology, high-speed curing for advanced electrodes, low-cobalt and cobalt-free cathodes, and high-performance computing for advanced processing, performance validation, and life prediction.
Research Areas
Bio-derived Materials for Additive Manufacturing
By integrating basic and early-stage applied energy capabilities, ORNL is leading the way to developing new bio-derived materials for a variety of applications using large-scale additive manufacturing.
High Performance Computing for Additive Manufacturing
ORNL is leading the Transforming Additive Manufacturing Through Exascale Simulation project (ExaAM), a project that uses supercomputing to improve additive manufacturing processes.
Creating Born-Certified Components
A number of software tools have been developed and shared with industry to improve the quality and performance of additive components. These tools are now being used to redefine how we design, build and qualify energy generation systems as well as aerospace and automotive components.
Hybrid Systems
ORNL is combining additive and subtractive capabilities in one system, creating a hybrid system with multiple advantages including cladding for multi and hybrid materials and embedded wireless sensors capable of in-situ monitoring.
Research and Development
Developed lower cost trim tool using additive manufacturing and composite materials made with carbon fiber and ABS thermoplastic.
Operated the world’s first large-scale 3D thermoset printer.
Used in situ data analytics to born certify parts every single time.
3D printed tooling for precast concrete molds for large-scale renovation project in New York City, proving more durable alternative to wooden tooling.
Expanded Big Area Additive Manufacturing capabilities to print large-scale polymer materials up to 13 ft long.
3D printed mold to directly infuse boat hulls.
Used bioderived composite materials to 3D print components of large outdoor pavilions.
Created manufacturing method combining 3D printing with traditional casting to produce damage-tolerant components composed of multiple materials.