Publications

Mar, 2026

Conference Paper

Multiplexing core & sheath extrusion system development for additive manufacturing for inner-bead multi-material capability

Single-feed polymer extruders are widely used in large-format additive manufacturing (AM) systems; however, the increasing demand for multi-material functionality within a single part has driven significant innovation in this field. One approach involves robotic pick-and-place operations, while another explores mechanical switching of feed lines during extrusion. Although…

Mar, 2026

Conference Paper

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

Additive Manufacturing (AM) of carbon fiber (CF) reinforced composite has received growing attention because of the design flexibility, superior mechanical properties, improved thermal properties, and weight reduction. Autoclave tooling was proven to be a successful application for large scale AM technology. The capital cost, and cost associated with heating, and cycle tim…

Dec, 2025

Journal

Electroslag additive manufacturing: A pathway for high throughput near net shape production

Electroslag Additive Manufacturing (ESAM), a new high-throughput additive manufacturing (AM) method that combines Electroslag Strip Cladding (ESC) and wire arc AM (WAAM) is introduced. This combination enables the high deposition rate of ESC (more than 20 kg/h with a 60 mm strip electrode) to benefit from the precise geometric control of WAAM. As a precursor to ESAM, the E…

Sep, 2025

Journal

Multiplexing Extrusion System Development for Increased Throughput, Flow Accuracy and Improved Microstructure

As additive manufacturing technologies advance and 3D-printers get larger, there is a constant need for larger extruders with higher throughput to quickly construct objects. Extruders can continually be made larger, but the weight of an extruder grows faster than its output, and larger/heavier extruders require a stiffer and more expensive gantries or robots to carry and c…

May, 2025

ORNL Report

Advanced Manufacturing and Materials for Hydropower: Challenges and Opportunities

Hydropower is a well-established industry that has been largely contributing to the global generation of clean and renewable energy for more than a century. In the United States in 2021, it accounted for 30% of all renewable energy generation and 6.1% of the total energy portfolio. Hydropower technology and designs have been optimized throughout the years, but manufacturin…

Mar, 2025

Journal

The Cost of Scaling Up in Large-Format Additive Manufacturing

Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m3, these printers have pushed the boundaries of achievable print volume while allowing the ut…

Jul, 2024

ORNL Report

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

May, 2024

ORNL Report

Additive Manufacturing for Large Displacement Unmanned Underwater Vehicles (LDUUVs)

Mar, 2024

Journal

Large Format Composite Additive Manufacturing for Low-Head Hydropower

Hydropower with a small elevation change from inlet to outlet, known as “low-head” hydropower, is a relatively untapped resource for reliable green power generation. One major barrier to entry is the cost of the components needed to generate the power. Each installation site is unique, with various head levels, flow rates, and other unique site characteristics that drive u…

Dec, 2023

ORNL Report

Candidate Core Designs for the Transformational Challenge Reactor

Dec, 2023

Conference Paper

Pressure Vessel Design Optimization of the Transformational Challenge Reactor

Dec, 2023

Journal

Candidate Core Designs for the Transformational Challenge Reactor

Early cycle activities under the Transformational Challenge Reactor (TCR) program focused on analyzing and maturing four reactor core design concepts: two fast-spectrum systems and two thermal-spectrum systems. A rapid, iterative approach has been implemented through which designs can be modified and analyzed and subcomponents can be manufactured in parallel over time fram…