Oak Ridge Today

ORNL making molds to help produce COVID-19 test tubes

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An example of a 3D printer, the Cincinnati Machine, is pictured above at work in Oak Ridge National Laboratory’s Manufacturing Demonstration Facility in Hardin Valley on Dec. 29, 2014. (Photo courtesy of Oak Ridge National Laboratory, U.S. Dept. of Energy)

Engineers at Oak Ridge National Laboratory are making metal molds that companies will use to manufacture plastic tubes for COVID-19 test kits.

The work has been cited in two federal coronavirus task force press conferences at the White House this week.

On Monday, Brad Smith, a federal health official, said the ORNL work could help supply more than 40 million collection tubes per month in the next several weeks. Smith grew up in Knoxville, and he has been a business leader and entrepreneur, and served in Tennessee state government. He is now deputy administrator and director of the U.S. Centers for Medicare and Medicaid Services.

The ORNL work was also cited by President Donald Trump on Sunday.

The ORNL engineers are using additive manufacturing to produce the metal molds for the COVID-19 test kits. Additive manufacturing is the process of making an object by printing it with a material layer by layer. Printers known as 3D printers— some large, some small—can be used.

[Read more…]

ORNL, UMaine to work on 3D printing with wood products

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On Thursday, officials announced a new research collaboration between the University of Maine and the U.S. Department of Energy’s Oak Ridge National Laboratory that they say will advance efforts to 3D print with wood products, creating a new market for Maine’s forest products industry. Pictured above among the officials are U.S. senators Susan Collins, center; Lamar Alexander, third from right; and Angus King, third from left; and Daniel Simmons, the assistant secretary for energy efficiency and renewable energy at DOE, as well as leaders from UMaine and ORNL. The officials were in Washington, D.C., on Thursday, May 2, 2019, to announce the launch of this large-scale bio-based additive manufacturing program. (Photo courtesy office of Sen. Susan Collins)

A partnership between the University of Maine and Oak Ridge National Laboratory will use ground-up trees and bioplastics to make “very strong plastics” that can be used in 3D printing, officials said Thursday.

The 3D printing, which will print items one layer at a time, could be used to make boat hull molds, shelters, building components, and tooling for composites and wind blades, among other possibilities.

The $20 million project will be funded by the U.S. Department of Energy’s Advanced Manufacturing Office.

ORNL is considered the leading laboratory for the type of work known as additive manufacturing, said U.S. Senator Lamar Alexander, a Tennessee Republican who was among the officials at the announcement in Washington, D.C., on Thursday.

[Read more…]

ORNL, University of Maine to announce $20 million 3D printing manufacturing partnership

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ORNL Manufacturing Demonstration Facility Entrance
New additive manufacturing technologies are being explored at DOE’s Manufacturing Demonstration Facility at ORNL. (Photo courtesy ORNL)
Lamar Alexander
Lamar Alexander

Three U.S. senators, Oak Ridge National Laboratory, and the University of Maine on Thursday will announce a $20 million 3D printing manufacturing partnership that will help the forest products industry, officials said Wednesday.

The announcement is scheduled for 11:30 a.m. Thursday in Washington, D.C. You can watch it here.

The three U.S. senators joining ORNL and the University of Maine at the announcement will be Susan Collins, a Maine Republican; Lamar Alexander, a Tennessee Republican; and Angus King, a Maine Independent.

They will announce the launch of a large-scale bio-based additive manufacturing, or 3D printing, program. 3D printing prints items a layer at a time.

[Read more…]

ORNL wins nine R&D 100 Awards        

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A close-up look at the Open Port Sampling Interfaces for Mass Spectrometry, one of Oak Ridge National Laboratory’s seven 2016 R&D 100 Award winners. (Photo courtesy ORNL)

A close-up look at the Open Port Sampling Interfaces for Mass Spectrometry, one of Oak Ridge National Laboratory’s seven 2016 R&D 100 Award winners. (Photo courtesy ORNL)

 

Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory have received nine R&D 100 Awards in recognition of their significant advancements in science and technology, a press release said. The honorees were recognized in November at the 55th annual R&D 100 Conference, sponsored by R&D Magazine.

The awards, known as the “Oscars of Invention,” honor innovative breakthroughs in materials science, biomedicine, consumer products, and more from academia, industry, and government-sponsored research agencies. This year’s nine honors bring ORNL’s total of R&D 100 awards to 210 since their inception in 1963, the press release said.

ORNL researchers were recognized for the following innovations:

ACMZ Cast Aluminum Alloys were developed by a team of researchers from ORNL with Fiat Chrysler Automobile U.S. and Nemak U.S.A.

ACMZ aluminum alloys are a new class of affordable, lightweight superalloys capable of withstanding temperatures of almost 100-degree Celsius more than current commercial alloys while providing exceptional thermomechanical performance and hot tear resistance.

Common commercial alloys soften rapidly at high temperatures, limiting their use in next-generation vehicles, while other alloys that can withstand elevated temperatures are cost prohibitive and difficult to cast. ACMZ alloys were developed using a suite of atomic-level characterization and computation tools, resulting in a strong, stable, and versatile material capable of withstanding the stressful conditions of next-generation high-efficiency combustion engines, the press release said. [Read more…]

ORNL 3D-prints first submersible hull for U.S. Navy

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U.S. Energy Secretary Rick Perry takes a picture of the submersible hull 3D printed for the U.S. Navy at the Oak Ridge National Laboratory Manufacturing Demonstration Facility on Monday, May 22, 2017. (Photo by John Huotari/Oak Ridge Today)

U.S. Energy Secretary Rick Perry takes a picture of the submersible hull 3D-printed for the U.S. Navy at the Oak Ridge National Laboratory Manufacturing Demonstration Facility in Hardin Valley on Monday, May 22, 2017. (Photo by John Huotari/Oak Ridge Today)

 

The U.S. Navy teamed up with Oak Ridge National Laboratory to print the military’s first 3D-printed submersible hull in just four weeks. The parts were printed in just days, rather than weeks, and production costs were cut by 90 percent.

The hull was printed at ORNL’s Manufacturing Demonstration Facility in Hardin Valley through a partnership with the Navy’s Disruptive Technology Lab, according to a story published July 20 by the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy. ORNL is a DOE laboratory.

“ORNL and the Navy saw this is as an opportunity to bring together their resources and expertise in a partnership with the potential to revolutionize manufacturing in the defense sector,” the DOE story said. “Not only can the Navy find new ways to reduce traditional costs associated with manufacturing, but the lessons learned from this project will help ORNL further explore 3D printing applications in the boating industry, aerospace, buildings, and anything that requires a large, resilient structure. Partnerships like these help drive economic growth and reinforce our national security.”

The team working on the 3D-printed submersible hull needed to create a 30-foot proof-of-concept hull out of carbon fiber composite material, DOE said. The prototype vessel is called the Optionally Manned Technology Demonstrator, and it could be used to deploy logistics capabilities and sensors. Future vessels will need to be manufactured faster and incorporate new designs to support Navy missions, DOE said. [Read more…]

ORNL’s Gibson named SME outstanding young engineer

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Brian T. Gibson (Photo courtesy ORNL)

Brian T. Gibson (Photo courtesy ORNL)

Brian T. Gibson, a postdoctoral research associate at the U.S. Department of Energy’s Oak Ridge National Laboratory, has been named one of the SME Outstanding Young Manufacturing Engineers for 2017.

Gibson has doctorate and master’s degrees in mechanical engineering from Vanderbilt University and a bachelor’s degree in mechanical engineering from the West Virginia University Institute of Technology, a press release said. He works in the Materials Processing and Joining group in the Materials Science and Technology Division at ORNL.

Before joining ORNL, Gibson studied as a Tennessee Space Grant fellow in the Vanderbilt University Welding Automation Laboratory. His research focuses on technical challenges at the intersection of robotics and materials processing, with specific research interests that include solid-state joining, additive manufacturing, in-process quality monitoring, robotic force control, and signal processing, the press release said.

UT-Battelle manages ORNL for DOE’s Office of Science. The Office of Science is the single largest supporter of basic research in the physical sciences in the United States, and is working to address some of the most pressing challenges of our time, the press release said. For more information, visit http://science.energy.gov/.

Curious about 3D printed vehicles, including excavator? ORNL has posted photos

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Oak Ridge National Laboratory has helped produce the first fully functional excavator that uses parts made through additive manufacturing, or 3D printing. The excavator is pictured above on Feb. 27, 2017. (Photo courtesy of Oak Ridge National Laboratory, U.S. Dept. of Energy)

Oak Ridge National Laboratory has helped produce the first fully functional excavator that uses parts made through additive manufacturing, or 3D printing. The excavator is pictured above on Feb. 27, 2017. (Photo courtesy of Oak Ridge National Laboratory, U.S. Dept. of Energy)

 

Oak Ridge National Laboratory has helped produce the first fully functional excavator that uses parts made through additive manufacturing, or 3D printing.

The excavator, part of a working demonstration known as Project AME, was made in collaboration with ORNL partners in industry, government, and academia. The project helps showcase a range of industrial applications for 3D printing, ORNL said.

Additive manufacturing is the process used to build something one layer at a time. Rather than ink, 3D printers use polymers.

One of the most well-known examples is the Shelby Cobra car 3-D printed on a large-scale polymer printer at ORNL’s Manufacturing Demonstration Facility in Hardin Valley. President Barack Obama and Vice President Joe Biden admired that vehicle—and joked about taking it for a spin—during a trip to East Tennessee in January 2015.

ORNL has been involved in other projects using 3D printing that have attracted attention, and the lab has posted photos of its 3D printed vehicles. You can see them here. [Read more…]

ORNL, Boeing set Guinness World Record with 3D printed tool for Boeing 777X wing part

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GUINNESS WORLD RECORDS measurement of ORNL-Boeing trim tool Aug 29 2016

Official measurement of the 3D printed trim tool co-developed by Oak Ridge National Laboratory and The Boeing Company exceeded the required minimum size to achieve the Guinness World Records title of largest solid 3D printed item. Pictured above on Monday, Aug. 29, 2016, is Guinness World Records Judge Michael Empric. (Photo courtesy ORNL, U.S. Department of Energy)

 

HARDIN VALLEY—A tool made by Oak Ridge National Laboratory has set a world record for largest solid item manufactured on a 3D printer. Guinness World Records confirmed the tool’s measurements during a visit to ORNL’s Manufacturing Demonstration Facility in Hardin Valley on Monday.

The trim-and-drill tool measures 17.5 feet long, 5.5 feet wide, and 1.5 feet tall. It’s comparable in length to a large sport utility vehicle and weighs approximately 1,650 pounds.

It will be used to help make a wing part on the Boeing 777X airplane, a passenger jet. After ORNL completes some testing, Boeing will evaluate the tool in the company’s new production facility in St. Louis and then provide information to ORNL about its performance.

ORNL printed the trim-and-drill tool in only 30 hours on a 3D printer at the Manufacturing Demonstration Facility in Hardin Valley using mostly ABS (acrylonitrile butadiene styrene) mixed with about 20 percent carbon fiber. ABS is the same material used to produce Legos, and it’s a tough, strong polymer, said Bill Peter, MDF director.

Judge Michael Empric said Guinness World Records had set a minimum measurement of 10.5 cubic feet for the new largest solid 3D printed item, which is a new category. The Boeing tool printed by ORNL measured much larger, 82.4 cubic feet, Empric said.

The original tool was printed in one piece and was larger, but it was trimmed down, Empric said. [Read more…]

ORNL, Boeing to receive Guinness World Records title for largest solid 3D printed item

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ORNL Manufacturing Demonstration Facility Polymer Printer

This large-scale polymer printer at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility was used to fabricate the Shelby Cobra. (Photo by John Huotari/Oak Ridge Today)

 

Note: This story was updated at 2:45 p.m.

Oak Ridge National Laboratory and the Boeing Company are expected to receive the Guinness World Records title for largest solid 3D printed item, a media advisory said.

On Monday, an official Guinness World Records judge will measure and award the title of largest solid 3D printed item to ORNL and Boeing for a 3D printed tool used in manufacturing the Boeing 777X passenger jet. The media has been invited.

The invitation-only ceremony is at 11 a.m. Monday, August 29, at ORNL’s Manufacturing Demonstration Facility at 2370 Cherahala Boulevard, off Pellissippi Parkway at Hardin Valley Road. [Read more…]

ORNL, Strangpresse LLC sign additive manufacturing patent license agreement

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ORNL Manufacturing Demonstration Facility Entrance

New additive manufacturing technologies are being explored at DOE’s Manufacturing Demonstration Facility at ORNL. The MDF is on Hardin Valley Road in west Knox County. (Photo courtesy ORNL)

 

The U.S. Department of Energy’s Oak Ridge National Laboratory and Strangpresse LLC of Youngstown, Ohio, have signed a non-exclusive licensing agreement on a portfolio of ORNL patents related to large-scale additive manufacturing.

ORNL is leading advances in the production of large-scale 3-D printed materials, refining industrial processes to decrease costs and increase efficiency.

Under the agreement, Strangpresse, a Hapco Inc. affiliate, may make, use, or sell the lab’s patented developments of materials, processes and controls that enable the manufacture of parts much larger than current standards.

“We’re very pleased to be joining with ORNL to carry large-scale additive manufacturing technology to the marketplace,” said Strangpresse President Chuck George. “Our leadership team has over 70 years of experience in the thermoplastics extrusion industry, and we see this partnership as a great opportunity to expand this technology.” [Read more…]

ORNL: Car, building are 3D-printed, can power each other

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ORNL 3D-Printed House and Vehicle on Sept. 24, 2015

A 3D-printed vehicle and building that were part of a nine-month research demonstration project were unveiled on Industry Day at ORNL on Wednesday, Sept. 23, 2015. The natural gas-powered car and solar-powered building can provide electricity to each other. (Photo by John Huotari/Oak Ridge Today)

 

A car and house built using large-scale 3D printers at Oak Ridge National Laboratory can provide power to each other, and they’re part of a project designed to answer “what if” questions that could lead to innovations in building and car construction and energy use, storage, and consumption, researchers and officials said Wednesday.

The 210-square-foot house—it’s a solar-powered building—and the printed utility vehicle—officials affectionately call it a PUV—were printed at ORNL’s Manufacturing Demonstration Facility on Hardin Valley Road.

They were unveiled at ORNL on Wednesday during the lab’s first-ever Industry Day. The building and PUV are part of a project called the Additive Manufacturing Integrated Energy, or AMIE, demonstration.

Additive manufacturing is the process used to build something one layer at a time. One of the most well-known examples is the Shelby Cobra car 3-D printed on a large-scale polymer printer at the MDF. President Barack Obama and Vice President Joe Biden admired that vehicle—and joked about taking it for a spin—during a trip to East Tennessee in January. [Read more…]

HED: Silica ‘spiky screws’ could enhance industrial coatings, additive manufacturing

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It took marine sponges millions of years to perfect their spike-like structures, but research mimicking these formations may soon alter how industrial coatings and 3-D printed objects are produced.

A molecular process developed by researchers at Oak Ridge National Laboratory paves the way for improved silica structure design by introducing microscopic, segmented screw-like spikes that can more effectively bond materials for commercial use.

The study, conducted by Jaswinder Sharma and his colleagues Panos Datskos and David Cullen, has been published in Angewandte Chemie International Edition. Authors said other applications of the screw-like spikes could include coatings for eyeglasses, television screens, commercial transportation, and even self-cleaning windows and roofs in rural and urban environments.

Created by emulsion droplets applied to a silica particle’s surface, the new, segmented spikes offer an alternative tool for material scientists and engineers that can better maintain and fuse bonds within a variety of microstructures. [Read more…]