Oak Ridge Today

3-D printed Shelby Cobra highlights ORNL R&D at Detroit Auto Show

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Shelby Cobra 3D Print at ORNL

This Shelby Cobra sports car, 3D-printed at the U.S. Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory, will be on display this week at the Detroit Auto Show Technology Showcase. (Photo courtesy ORNL)

 

With a 3-D printed twist on an automotive icon, the U.S. Department of Energy’s Oak Ridge National Laboratory is showcasing additive manufacturing research at the 2015 North American International Auto Show in Detroit.

ORNL’s newest 3-D printed vehicle pays homage to the classic Shelby Cobra in celebration of the racing car’s 50th anniversary. The 3-D printed Shelby will be on display January 12-15 as part of the show’s inaugural Technology Showcase.

Researchers printed the Shelby car at DOE’s Manufacturing Demonstration Facility at ORNL using the Big Area Additive Manufacturing, or BAAM, machine, which can manufacture strong, lightweight composite parts in sizes greater than one cubic meter. The approximately 1,400-pound vehicle contains 500 pounds of printed parts made of 20 percent carbon fiber. [Read more…]

Obama visit spotlights sports car printed by UT engineers at ORNL

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Shelby Cobra 3D Printed Cobra

University of Tennessee engineering students Andrew Messing and Alex Roschli printed this Shelby Cobra at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility. The car was on stage during President Obama’s visit to Techmer PM in Clinton on Friday. (Photo courtesy UT)

 

CLINTON—President Obama took the stage at Techmer PM in Clinton on Friday to announce that the University of Tennessee in Knoxville will head a $259 million advanced manufacturing project and that Oak Ridge National Laboratory will play a key role. The president shared the spotlight with a shiny example of innovation, research, and collaboration between the two—a Shelby Cobra 3D printed car.

The car was highlighted during Obama’s visit as an example of the changing world of manufacturing. It was produced with major contributions from a pair of student interns from UT’s College of Engineering—Alex Roschli and Andrew Messing, a press release said.

Roschli and Messing, both seniors in the Department of Electrical Engineering and Computer Science, are doing internships at ORNL, where the car was printed at the Manufacturing Demonstration Facility. [Read more…]

UT engineering students help ORNL, Local Motors print drivable 3D car

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3D Car

John Rogers, co-founder and CEO of Local Motors, left, and Douglas Woods, president of the Association for Manufacturing Technology, drive away from the International Manufacturing Technology Show in Chicago over the weekend in a car printed with the help of UT students. (Photo courtesy UT)

 

KNOXVILLE—The only “car” that most people associate with printers is a “car-tridge” of ink, but that may soon change thanks in part to several students at the University of Tennessee in Knoxville.

UT, Oak Ridge National Laboratory, Local Motors, Cincinnati Incorporated, and Oak Ridge Associated Universities teamed up to print a working, drivable car over the weekend at the International Manufacturing Technology Show in Chicago.

The Strati 3D, officially produced by Local Motors, which has an office on Market Square in Knoxville, highlighted the show and placed what sounds like a product of science fiction firmly in the realm of reality.

“This brand-new process disrupts the manufacturing status quo,” said John B. Rogers Jr., chief executive officer of Local Motors. “It changes the consumer experience and proves that a car can be born in an entirely different way.” [Read more…]

Wounded veteran finds new way to serve by training for career in 3D printing

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Joseph Grabianowski

Joseph Grabianowski

New training program prepares veterans, others to enter advanced manufacturing workforce

While 26-year-old wounded veteran Joseph Grabianowski has inspired Americans with his harrowing war story, someday he may be nationally known for building highly efficient exhaust systems for cars and trucks using 3D printing technology.

Grabianowski—pictured at left at the U.S. Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory in front of a 3D printer holding a 3D-printed DOE seal and the plastic material from which it was made—is part of the Energy Department’s inaugural Energy Efficiency and Renewable Energy Advanced Manufacturing Internship. The pilot program is designed to provide accelerated, hands-on career training for veterans and next-generation engineers to prepare them to immediately enter the workforce of the growing advanced manufacturing industry.

Grabianowski stepped on an IED while deployed with his Army unit in Kandahar Province, Afghanistan, in May 2012. Damage from the blast required a rare, radical amputation of his lower body. He had long dreamed of being a U.S. Marshal but knew his path would now lead in a new direction. In a December 2013 interview with USA Today, Grabianowski said, “I still love my country…even though I can’t go be a marshal now, I can still go do something that would be a good service to my country.”

Barely two years later, his successful recovery is a testament to his personal will and determination. This self-proclaimed techie now envisions a career for himself in what he calls the “future of manufacturing,” which is additive manufacturing, also known as 3D printing. Through this pioneering program offered by the Energy Department’s Advanced Manufacturing Office, Oak Ridge Associated Universities, Pellissippi State Community College, and ORNL, Grabianowski is receiving the training needed to make his career goals a reality and prepare him to succeed in the additive manufacturing world.

“Where this industry is going to boom is right here in Oak Ridge,” Grabianowski said, “and the best engineers in the field are available through this program to teach me.” [Read more…]

Spotlight: Knoxville mayor tours ORNL’s manufacturing demonstration facility

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Madeline Rogero at Manufacturing Demonstration Facility

Foreground, from left, ORNL’s Ryan Dehoff shows 3-D printed parts to Knoxville Mayor Madeline Rogero, accompanied by ORNL Director Thom Mason and Craig Blue, director of ORNL’s advanced manufacturing program and the Manufacturing Demonstration Facility. (Photo by Jason Richards/ORNL)

 

Knoxville Mayor Madeline Rogero recently visited the U.S. Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory.

Rogero had been invited to participate as a “Maker Mayor” at the June 18 White House Maker Faire. Oak Ridge Mayor Tom Beehan also attended.

When Roger returned, she asked ORNL for more information on additive manufacturing, the lab said.

The tour of the Manufacturing Demonstration Facility gave Rogero an overview of the facility and the research underway there.

ORNL, Ohio company work together on new large-scale 3-D printing system

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ORNL and Cincinnati Inc. CRADA

From left are David Danielson, DOE assistant secretary for energy efficiency and renewable energy; Johnny Moore; DOE site office manager, Andy Jamison, Cincinnati Inc. CEO; and U.S. Rep. Chuck Fleischmann. (ORNL photo/Jason Richards)

Technology seeks to provide new capabilities for auto, aerospace, other U.S. industries

Oak Ridge National Laboratory is partnering with Cincinnati Inc., a manufacturer of high quality machine tools located in Harrison, Ohio, to develop a large-scale polymer additive manufacturing (3-D printing) system.

The partnership aims to accelerate the commercialization of a new additive manufacturing machine that can print large polymer parts faster and more cheaply than current technologies. The partnership agreement supports the U.S. Department of Energy’s Clean Energy Manufacturing Initiative to increase the efficiency of the U.S. manufacturing sector and ensure that innovative clean energy technologies continue to be developed in America.

ORNL is a DOE lab. [Read more…]

ORNL, Local Motors agree to pave way to world’s first 3-D printed vehicle

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Local Motors and ORNL on 3-D Printing

A new partnership between Local Motors and ORNL will explore vehicle design and construction using 3-D printing technologies. The project will make use of equipment at DOE’s Manufacturing Demonstration Facility, such as the large-scale additive manufacturing machine operated here by ORNL’s Peter LLoyd.

Local Motors Inc. and Oak Ridge National Laboratory have signed a new partnership to develop and deliver technology to produce the world’s first production 3-D printed vehicle.

The cooperative research and development agreement, or CRADA, between Local Motors and ORNL will explore ways to make vehicle construction more efficient—including by lower production time, costs, and part count—and raise standards for control, safety, aesthetics, and mechanical flexibility.

“The primary tool in this drive for efficiency is a combination of material science and cutting-edge advanced manufacturing techniques that are both additive and subtractive,” an ORNL press release said. ORNL is part of the U.S. Department of Energy’s national laboratory system.

“By invoking the principle of open-source, this partnership—and future efforts like it—will drive a true paradigm shift in hardware product development and automotive manufacturing technologies,” said Jay Rogers, co-founder and chief executive officers of Local Motors. “Just as exciting as the vision of delivering the first direct digital manufactured car is that we will be engaging future consumers to contribute and evangelize its creation. We are living in a time when speed to market trumps slow-going protectionism. Local Motors’ open development platform is what delivers this very speed.” [Read more…]

Picture: DOE director of economic impact, diversity visits ORNL

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Dot Harris at Oak Ridge National Laboratory

From left, Dot Harris, director of the U.S. Department of Energy’s Office of Economic Impact and Diversity, and Michael Colbert, deputy director of DOE’s Office of Diversity and Inclusion, listen as Research Alliance in Math and Science student Darius Degraffenried presents his research. (Photo by ORNL’s Jason Richards)

The U.S. Department of Energy’s Dot Harris, director of the Office of Economic Impact and Diversity, visited Oak Ridge National Laboratory Thursday and Friday.

Harris spoke at the Research Alliance in Math and Science banquet Thursday evening, and she attended a RAMS poster session that preceded the dinner.

Her agenda also included visits to ORNL’s supercomputing facilities, Spallation Neutron Source, the Carbon Fiber Technology Facility, and the Manufacturing Demonstration Facility, as well as discussions on the lab’s education, outreach, partnerships, and small business programs. [Read more…]

ORNL makes low-cost carbon fiber available to American manufacturers

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Carbon Fiber Technology Facility

Operated by Oak Ridge National Laboratory, the Carbon Fiber Technology Facility is accepting proposals from companies that want to test low-cost carbon fibers manufactured at the pilot scale plant. Pictured here are textile-grade acrylic fibers entering the first of four oxidation ovens, where they gradually turn from white to yellow, auburn, brown, then black. Once fully oxidized, the fiber is ready to run through the higher-temperature furnaces, which convert the oxidized fiber to carbon fiber. (Submitted photo)

Companies interested in testing the latest in low-cost carbon fiber have a new opportunity to partner with the U.S. Department of Energy’s Carbon Fiber Technology Facility.

The CFTF, operated by Oak Ridge National Laboratory as part of the department’s Clean Energy Manufacturing Initiative, opened earlier this year to find ways to reduce carbon fiber production costs and to work with the private sector to stimulate widespread use of the strong, lightweight material.

In its first months of operation, the CFTF used traditional raw materials to assure the new pilot scale manufacturing line would produce a commercial-quality product. With that goal accomplished, the facility now will use less expensive “precursor” materials that can be turned into carbon fiber more cost-effectively. [Read more…]

UT names advanced manufacturing expert as Governor’s Chair with ORNL

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Sudarsanam Suresh Babu

Sudarsanam Suresh Babu

Sudarsanam Suresh Babu, an authority in the production, design, and performance of transforming materials into parts, has been named the 11th University of Tennessee-Oak Ridge National Laboratory Governor’s Chair.

Babu will serve as Governor’s Chair for Advanced Manufacturing. He begins on July 1.

Babu, a professor in the Welding Engineering Program in the Department of Materials Science and Engineering at The Ohio State University, directed a National Science Foundation Industry and University Cooperative Research center focused on materials joining for energy applications. [Read more…]

Local FIRST robotics teams dominate regionals, advance to national competition

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First Robotics Competition

From left, Oak Ridge High School’s Andreas Franco feeds discs into the team’s robot as Tag Groff, Oak Ridge National Laboratory mentor Mark Buckner, and Amelia DiAngelo manage the controls. (Photo by Jason Richards/ORNL)

Frisbee-flinging robots took over the Knoxville Convention Center last weekend, as thousands of high school students, mentors, and volunteers gathered for the third annual FIRST robotics Smoky Mountains regional competition.

Local teams Hardin Valley Academy, Oak Ridge High School, and Halls High School netted the championship title in a nail-biting finale at the regional event, qualifying them to compete in the national finals held April 24-27 in St. Louis. A team from Roane County High School, which won the Rookie All Star award, is also bound for nationals. The four high schools are among 14 teams sponsored by UT-Battelle, the managing contractor of Oak Ridge National Laboratory.

The FIRST robotics competition gives high school teams six weeks to design, build, and program a complex robot that can meet the intense demands of the year’s game. Throwing discs and climbing pyramids were among the challenges of the 2013 game, called Ultimate Ascent. [Read more…]

ORNL helps kick off 2013 FIRST robotics season

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First Robotics Competition

Students try their hand at manipulating a Remotec robotic system at a kickoff event for the 2013 FIRST Robotics Competition at ORNL’s Manufacturing Demonstration Facility on Saturday. (Submitted photo)

Students from dozens of area high schools piled into Oak Ridge National Laboratory’s Manufacturing Demonstration Facility on Saturday to get a sense of the obstacles they will be battling over the next six weeks. Hundreds of students, parents, and mentors attended the kickoff event for the 2013 FIRST robotics competition, a nationwide event in which students design and build complex robots that can tackle the challenges of a specially designed game.

This year’s challenge, which involves robots that can throw discs and climb pyramids, was revealed via simulcast on Saturday morning. Teams were then able to view a full-scale version of the competition field and hold mock games on it. The field, sponsored by Tech 2020 and assembled by the Hardin Valley Academy FIRST Alumni Club at ORNL’s Manufacturing Demonstration Facility, or MDF, is available for all local teams to use during the build season.

[Read more…]