OAK RIDGE NATIONAL LABORATORY

“Our goal is to bring long-term immediate and cost-effective 

clean energy solutions to the manufacturing industry. By 

working together, we can implement logical steps and 

activities to achieve the nation’s carbon goals.”

Sachin Nimbalkar, Group Leader, Manufacturing Energy Efficiency Research and Analysis

Advanced Manufacturing

CONTROLLING 

microstructure 

in metal parts

CUTTING 

advanced 

fiber costs

ADDITIVE

MANUFACTURING

large-scale objects 

such as cars, houses, 

and tooling molds

CREATING

upcycling, recycling, and 

recovery of materials

QUALIFYING

additively 

manufactured 

components

Oak Ridge National Laboratory (ORNL) draws upon unmatched capabilities in materials, neutron studies, and computational 

science to develop innovative technologies to assist manufacturing companies of all sizes in the deployment of at-scale solutions 

that lower production costs and improve US economic competitiveness. Researchers focus on decarbonizing manufacturing 

operations through the development of novel clean energy technologies. In collaboration with co-located industry partners, 

researchers investigate next-generation materials, simulations, data analytics, and artificial intelligence to create and demonstrate 

new advanced manufacturing systems and processes. 

Research, Development, and Deployment

Energy-efficient manufacturing and industrial decarbonization—Using 

chemical engineering methods to discover and demonstrate effective renewable and 

alternative feedstocks as sources of energy, to reduce or eliminate dependency on 

fossil fuels, and applying innovations to manufacturing processes in industry to reduce 

energy use and increase resiliency, sustainability, and US economic competitiveness

Composites, advanced fibers, and sustainable manufacturing—

Converting sustainably derived natural feedstocks and developing novel conversion 

processes to create materials with desirable traits such as strength, ductility, or 

flexibility; testing processes at industry scale for the benefit of manufacturers and end 

users; developing circular economies, where materials are put back into use rather 

than discarded to help mitigate waste and pollution and reduce manufacturing 

impacts on climate change

Precision manufacturing and machining—Designing, implementing, 

and scaling up next-generation manufacturing systems through the integration 

of robotics, automation, controls, and machine tools including novel large-scale 

metal wire arc and laser systems with multiaxis controls and powder systems with 

the ability to manufacture crack-free, highly nonweldable alloys to demonstrate 

microstructure control

Secure and digital manufacturing—Developing a digital manufacturing platform 

and a cyber-secure manufacturing ecosystem by integrating manufacturing systems 

enabled by advanced data analytics, metrology, characterization, process control, and 

secure communication; research capabilities in communication, computing, storage, and 

user interface for advanced manufacturing process analysis, modeling, and control
Oak Ridge National Laboratory is managed by UT-Battelle LLC for the US Department of Energy January 2022

Recent Impacts

Additive manufacturing—Developed a data framework containing modeling and real-time data 

acquisition to recognize variations and defects in a broad range of powder bed additive manufacturing 

technologies; designed and fabricated an infrastructure-scale concrete deposition system for energy 

generation applications

Decarbonizing industry—Initiated virtual in-plant trainings through the Better Plants 

program, working with 600 industrial participants and achieving more than 180 hours and 

$6 million in energy cost savings

Advanced composites—Created the first 3D-printed thermal protection shield for use 

in a space mission, launched in August 2021 to the International Space Station

Large-scale applications—Demonstrated the largest-ever steel print—947 layers and 

measuring 7 feet tall, and 2 feet wide—using new multirobot-coordinated deposition and a 

welder that deposits an order of magnitude faster than conventional welders

Industry partnerships—Worked with industry to develop and deploy a commercial 

tool and software that work together to increase material removal rates by 232%, resulting 

in a total annual savings of more than $3.2 million

National Collaborations

ORNL is a founding member or partner in several national collaborations aimed at introducing clean 

energy solutions to the manufacturing industry including the Hub and Spoke Partnership with the 

University of Maine, Institute for Advanced Composites Manufacturing Innovation, Cyber Manufacturing 

Innovation Institute, Critical Materials Institute, Innovation Crossroads, and Better Plants Program.

CONTACT:

William Peter

Advanced Manufacturing

Office Program Manager

peterwh@ornl.gov

865-241-8113

One Bethel Valley Road, 

Oak Ridge, TN 37830

www.ornl.gov/

advanced

manufacturing

Unique Facilities

US Department of Energy (DOE) Manufacturing Demonstration Facility (MDF) creates and accelerates next-generation 

advanced manufacturing technologies, where materials, processes, and systems are holistically integrated to strengthen 

the US manufacturing base. Researchers at the MDF develop new tools and methods that are more 

cost-effective, efficient, and reliable for the nation’s security, economy, and energy portfolio. Through 

a robust technology transfer program, the MDF provides industry partners affordable 

and convenient access to facilities, tools, and expertise to facilitate rapid 

deployment of new technologies and clean energy solutions.

DOE Carbon Fiber Technology Facility (CFTF) assists industry with 

overcoming the barriers associated with cost and technology scaling 

of low-cost fibers and associated composites, including product and 

market development. The CFTF identifies high-potential, low-cost 

raw materials such as textile, lignin, polymer, and hydrocarbon-based 

precursors and houses a highly flexible manufacturing line rated for 25 tons 

per year and a precursor melt-spinning line rated at 65 tons per year.

At the DOE Battery Manufacturing Facility (BMF), every 

aspect of battery production is analyzed, from raw materials 

and electrode dispersion preparation to finished product 

and performance testing. Partners can leverage the BMF’s 

capabilities and experts to integrate any component or 

material into a complete battery to analyze how well it 

works and how it can be improved.

250+

Co-located staff, 

students, industry 

partners

$1B+

Follow-on 

private

 investment

100+

Advanced 

manufacturing 

systems

32

R&D 100

Awards