![]() The participant will also participate and engage in meetings with other ORNL staff and industrial partners.Ĭhris Printer to Spray Coater Conversion for the Fabrication of Fuel Cell and Electrolyzer Electrodes Additionally, they will learn to operate the MedUSA system and control industrial wire-arc robots as well as run robot simulations. Programming and CAD will be used to implement these system improvements. They will also do some development in hardware to improve the quality of a 3D printed metal part. The participant will research and develop on optimizing dynamic toolpath allocation algorithms that improve the productivity and overall performance of the system. The selected participant will work on controls and system development for MedUSA, a multi-robot large scale metal additive manufacturing system. The selected student will learn through experience how a seasoned interdisciplinary team of engineers works together to solve complex open ended engineering problems, culminating in a public demonstration of the new system at the end of the summer (printing a 50+ft long object!).īrian and Controls for a Multi-robot Large Scale Metal Additive Manufacturing System To solve this problem and radically reduce the cost associated with large scale composite AM technologies, ORNL has been developing the Configurable Holonomic Additive Manufacturing Platform (CHAMP) consisting of a 100Kg payload serial manipulator mounted on a high capacity omnidirectional vehicle with a 75kg/hr polymer extruder for an end effector. Most 3d printers can only fabricate objects smaller than the printers themselves. The chosen participant will interface with seasoned engineers to design and carryout experiments, develop new manufacturing hardware and processes, and characterize the performance of produced components.īrian Format Freeform 3D Printing of Composites The project will use a welding technology based on hybrid electro slag cladding (H-ESC) combined with low-cost iron feed stock that contains direct reduced iron and iron oxide to deposit stacked beads of material with mechanical properties useful to the clean energy industry, demonstrating a clear path to large-scale casting replacement parts. The goal of this project is to develop an electricity-based manufacturing pathway to print cast iron replacement material directly from low-cost feedstock. Using a large serial manipulator the student will participate in fundamental research aimed at learning how to create near net shape steel parts directly from iron ore using a new 3D printing process being developed at ORNL. The student will gain experience in 3D modeling (SolidWorks), knowledge of welding and additive manufacturing, familiarity with fluid flow and general material science.Īmy to More - 3D Printing to Enable Lage Scale Casting Replacements The student will assist in conducting experimental process development for titanium deposition, including aiding with the design of a custom shielding gas device to increase the shielded (inert) volume around the weld. However, GMAW based deposition of titanium poses unique challenges for maintaining weld quality due to sensitivity to oxygen and reactive gases. Internship location: Oak Ridge, TN or virtualĪlex Metal Additive Manufacturing System for Titanium GMAW and Design of Custom Localized Arc Shielding Deviceĭeposition of titanium and titanium alloys presents an opportunity for metal additive manufacturing to produce new and complex parts for aerospace, naval, and other industries. ![]() Depending on the interests of the student, learning objectives can include any of the following C++ algorithm development, development of network communication protocols for software-software data exchange, g-code formatting an interoperability, and printing on an industrial-scale 3D printer. This project will give a student the opportunity to develop software for a variety of 3D printers as well as interact with a few. ![]() Development of new algorithms, GUI (graphical user interface) elements, and system integration is ongoing. This software package is written entirely in C++ using the Qt framework. ![]() ORNL Slicer 2 is a state-of-the-art slicing program developed at ORNL that supports more than a dozen unique additive manufacturing processes. The process uses many fundamental geometry processes to manipulate objects and develop text-based g-code output. Slicing is the process of taking a CAD (computer aided design) object and generating toolpaths for 3D printing. Citizenship is a requirement for this internship Project Description: ![]()
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