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Partnerships staff receive tech transfer honors
Two staff members at ORNL, Susan Ochs and Dan Vacar, were recognized for excellence in their fields at an awards event during the spring 2025 Technology Transfer Working Group, or TTWG, meeting in Washington, D.C., on May 29.
“Commercialization is one of the most important ways we turn federal research into real-world impact,” said Anthony Pugliese, chief commercialization officer and director of the Office of Technology Commercialization.
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Innovation Crossroads Fellows and staff joined LEEP participants from other national labs at Berkley Commons for Demo Day on May 21. Alumni shares successes in pitch sessions and connected with representatives from across government, academia and the startup ecosystem.
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Researchers have developed a tool that gives builders a quick way to measure, correct, and certify level foundations. The Flat and Level Analysis Tool examines a 360-degree laser scan of a construction site using ORNL-developed segmentation and machine learning algorithms. Read more.
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Innovation doesn't stay in the past at ORNL: a Material Transfer Agreement enables the legacy of the "Mouse House" to continue to influence genetic research and commercial industry.
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New ORNL Inventions
Reducing Weld Additive Part Distortion with Spot Compressions Integrated into the Build Process
202305365 // Manufacturing // Materials
Researchers developed a novel mechanical correction method to address thermal distortion in Wire Arc Additive Manufacturing (WAAM). This approach reduces warping in printed components by applying targeted compressive force, improving part accuracy and reliability. The technology supports the broader adoption of WAAM in industrial applications where dimensional stability is critical.
Modular Components for Chemical Vapor Deposition
202305387 // Materials // Energy and Utilities
In order to avoid the limitations and costs due to the use of monolithic components for chemical vapor deposition, we developed a modular system in which the reaction chamber can be composed of a top and bottom cone, nozzle, and in-situ reaction chambers. These components could be fabricated with plastics, ceramics, and metals by traditional or additive manufacturing processes. In this new design, the nozzle and the bottom cone are fabricated as individual pieces to allow an easy exchange. Furthermore, since it is desirable to produce chemical precursors as close as possible to the entrance of the reaction chamber, we designed a parallel small reaction chamber where solid precursors could be produced.
Grid Carbon Intensity Estimator (G-CIE)
202305440 // Transportation // Energy and Utilities
The Grid Carbon Intensity Estimator (G-CIE) is a geospatial analysis tool that enables stakeholders to estimate the carbon emissions associated with increased electricity demand—such as from vehicle charging—at the county level. This tool supports low-emission infrastructure planning as part of broader electrification strategies.
Multilayer Facer Barriers for Enhanced Thermal Stability in Rigid Foam Insulations
202305444 // Manufacturing // Energy and Utilities
The use of novel multilayer barrier facers improves the initial and long-term thermal performance of rigid foam insulation, commonly used in building, refrigeration, and aerospace applications. The innovation addresses minimizing the loss of low thermal conductivity blowing agents during foam production and thermal aging, a degradation of insulation effectiveness over time, by incorporating advanced facer films with diffusion-tight bonding between the foam and facers to minimize gas diffusion. This solution significantly improves the performance of insulations to retard thermal losses.
Spectroscopic Measurements to Evaluate Froth Floatation of Rare Earth Ores
202305449 // Materials // Chemicals
Researchers have developed an advanced spectroscopic screening method to evaluate the flotation of potential earth element (REEs) ores. This technique enables rapid, non-destructive assessment of collector adsorption on mineral surfaces, streamlining the discovery and optimization of floatation agents for REE.
Scientific Ontology-Based GPT Approach for Autonomous Software Development of Urban Digital Twins
202405579 // Energy and Utilities // Transportation
A new AI-powered decision support system improves how urban planners and logistics managers access and apply domain-specific knowledge. By enhancing data-driven and simulation-based decision-making, this technology helps overcome bottlenecks optimization for freight and urban systems.
Electrochemical Microreactor
202405678 // Energy and Utilities // Materials
The microreactor design addresses the need to understand molten salt-assisted electrochemical processes at a controlled scale, enabling real-time observation of structural changes and kinetics. Our invention allows the study and optimization of the electrochemical graphitization process. This microreactor provides real-time monitoring of structural transformations and reaction kinetics, offering valuable insights that optimize production. The compact design facilitates rapid modification of experimental variables, making it a versatile tool for various research and industrial applications. By enhancing our understanding and control over the graphitization process, the microreactor contributes to more efficient, cost-effective, and environmentally friendly graphite production.
Lattice Collimator for Enhanced Point Source Detection in Radiation Portal Monitors
202405796 // Security and Defense // Detectors and Sensors
A novel collimator design enhances the detection capabilities of radiation portal monitors (RPMs) by improving sensitivity to localized radioactive sources while reducing nuisance alarms from large, distributed sources. This innovation is particularly beneficial for border security and nuclear facility monitoring, where accurate and selective threat detection is critical.
Method to Operate High Substitution Rate Dual Fuel Engine from Low to High Loads
202405826 // Transportation // Energy and Utilities
A new combustion control strategy developed at Oak Ridge National Laboratory enables high substitution of methanol in marine engines using conventional or renewable pilot fuels. This approach supports significant reductions in fuel use and criteria emissions without sacrificing performance, expanding fuel options for the marine industry.
Vivaldi: A Machine Learning Approach to Inferring Building Height
202505875 // Security and Defense // Energy and Utilities
Researchers have developed a novel data-driven framework to enhance the accuracy of building height estimation at a building-by-building level, particularly for high-rise structures. Traditional methods often struggle to estimate the height of taller buildings due to data imbalance and classification inconsistencies. This innovation improves precision by segmenting the built environment into distinct categories, enabling tailored analysis that supports applications in energy modeling, disaster response, and urban planning.
Method of Calculating Residual Stress in the Laser Welded Joints of Dissimilar Metals
202505877 // Manufacturing
Oak Ridge National Laboratory and General Motors have developed a computational modeling tool that predicts residual stress and microstructural evolution in laser-welded joints made from dissimilar metals. This innovation addresses the challenge of crack formation and stress concentration during high-temperature joining processes. The tool supports process optimization to improve weld integrity, reduce manufacturing defects, and lower energy costs in industrial welding applications.
Improved Amide Synthetases for Nylon Synthesis
202505894 // Materials
Researchers have developed a biocatalytic platform to enhance the synthesis of key nylon monomers and related compounds using engineered enzymes. This innovation provides an alternative to traditional chemical methods by leveraging tailored enzyme variants with improved substrate compatibility. The platform offers new pathways for producing polymer precursors under mild conditions, enabling greater efficiency and potential environmental benefits.
Amide Synthetases for Production of Sequenced Oligoamides
202505895 // Materials
A novel enzymatic approach enables the synthesis of sequence-controlled polyamide oligomers from simple, nylon-relevant building blocks. This biosynthetic strategy mimics nature’s precision in protein assembly to construct co-polyamides with defined monomer arrangements, offering a path toward next-generation materials with tunable physical and chemical properties.
Protective Coatings for Solid-State Catholytes, Anolytes and Electrolytes
202505909 // Security and Defense // Transportation
This technology provides a novel method for protecting interfaces within solid-state batteries to enhance long-term stability and performance. By addressing degradation at critical junctions between battery materials, it offers a promising route to more durable, high-capacity energy storage systems.
Thermal Management for Stacked Die Power Module
202505914 // Energy and Utilities // Transportation
Researchers at Oak Ridge National Laboratory have developed an advanced thermal management design for stacked die power modules. This packaging innovation enhances heat dissipation in compact, high-density power electronics – crucial for next-generation applications such as electric vehicles. The approach reduces junction temperatures while maintaining power density, addressing one of the key limitations of vertical die stacking: effective heat extraction.
TraKit: A Comprehensive Human Mobility Science Framework
202505915 // Analytical Instrumentation //
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