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As the United States works towards achieving 100% clean energy by 2035, sourcing components for critical infrastructure can be a lengthy process rife with obstacles. A new, unique program for producing large metal parts aims to help revitalize American manufacturing, returning those services back to the U.S.
Oak Ridge National Laboratory’s (ORNL) new project titled “Rapid Research on Universal Near Net Shape Fabrication Strategies for Expedited Runner Systems,” or Rapid RUNNERS, received $15 million in funding over three years from the Department of Energy (DOE) in 2024. The goal of the project: utilize 3D printing, or additive manufacturing, as well as conventional tools, to produce runners for hydropower projects – a demonstration of which is being planned alongside project partner Tennessee Valley Authority.
Currently, runners are heavily produced overseas, and when an issue occurs, the process of fabricating and receiving replacements can take years, leading to lost money, time, and renewable energy. By utilizing automated additive manufacturing, metal components could be produced quickly.
The potential of additive manufacturing extends beyond the material benefits it provides. Since 2021, Oak Ridge Schools have purchased and written grants for equipment like water jet cutting systems, metal mills, and 3-D printers for its students, leading to school-brokered contracts with businesses seeking parts production.
HANDS-ON LEARNING
Oak Ridge High School’s (ORHS) Wildcat Manufacturing – a student-run business with the aim of honing customer interaction, design, and manufacturing skills – is robust. The school’s machine shop consists of eight commercial 3D printers, laser cutters, lathes, a nylon powder bed printer, five resin printers, and a 5-axis CNC machine.
Dr. Mark Buckner, a teacher at ORHS and retired ORNL researcher of 32 years, has a passion for the opportunities ORHS is creating for students, stating, “We’re not only producing things of value for our local partners but vibrant parts of the workforce.”
When the Institute for Advanced Composites Manufacturing Innovation (IACMI) settled on Knoxville, Tennessee, as the location for its 2023 Members Meeting, they wanted to create a memento for attendees. After some deliberation, IACMI settled on Wildcat Manufacturing to produce 300 custom pieces inspired by Knoxville’s Sunsphere.
Inspired by Wildcat Manufacturing’s work with IACMI, National Hydropower Association (NHA) hired the students to produce miniature hydropower turbines as keepsakes for attendees of Clean Currents – NHA’s tradeshow + conference. The mini-turbines were a huge hit at the event, which took place at the Oregon Convention Center in Portland, Oregon, from October 7-10. The student’s work embodies the spirit of innovation which defines Clean Currents, demonstrating not only the vocational skills necessary to fuel the future workforce but the people who will carry on the critical work of maintaining hydro’s benefits.
Motivated by the success of Wildcat Manufacturing, Dr. Buckner created a traveling program, iSchool, which he hopes will serve as a model – one that could be replicated across the United States. In addition to the program and his work at ORHS, Dr. Buckner and co-workers equipped a trailer with technology for a maker lab, and they have taken the trailer to elementary and middle schools across rural Tennessee to provide the experience of working with a range of technologies.
FOR MORE INFORMATION
To learn more about the story of Wildcat Manufacturing’s work with IACMI, check out the video here.
