ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 12 Industry’s technical and economic needs are constantly evolving. At the same time, implementing innovative ideas can be challenging for industry, amid months- and years-long lead times inherent in global supply chains. The Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory helps U.S. industry rapidly develop and deploy advanced manu- facturing technologies and materials that meet today’s needs and shape what comes next. Through close collab- oration, MDF and industry partners work to bolster domestic supply chains and forge a more efficient, innovative future for American manufacturing. This article introduces MDF and provides an inside look at how it engages with industry to solve pressing manufacturing challenges, particularly those that stifle advancement in energy and defense applications. ADVANCING SCIENTIFIC AND ECONOMIC OPPORTUNITIES The Department of Energy (DOE) established MDF in 2012 to provide industry with direct access to shared resources and diverse technical expertise to speed the adoption of advanced manufacturing. MDF is an “idea factory” and an example of place-based innovation. Similar to Lockheed Martin’s Skunk Works or Boeing’s Phantom Works divisions, MDF brings together a cross-section of scientists, engineers, and industry representatives, along with advanced manufacturing tools to creatively solve industry’s biggest manufacturing challenges. MDF is tasked with developing advanced manufacturing solutions that strengthen U.S. supply chains, increase American manu- facturing competitiveness, and develop the workforce to meet industry needs and national goals. With support from the DOE Office of Energy Efficiency and Renewable Energy’s Advanced Materials and Manufacturing Technologies Office, MDF pursues its mission through six key actions: • Engaging industry on a continuous basis • Leveraging national laboratory capabilities • Facilitating collaboration and co-location • Providing a clear path for technology transfer • Publicly demonstrating new technologies • Cultivating a network around advanced manufacturing In collaboration with industry, academic, and government partners (including not only DOE but also Department of Defense offices), MDF has pioneered a range of next-generation manufacturing technologies including: • Large-scale polymer printing • Laser, electron beam, and binder jetting powder bed printing • Large-scale metal printing, such as wire arc additive manufacturing (WAAM) and laser-based wire deposition • Convergent manufacturing platforms utilizing both additive and subtractive capabilities • High-performance composites and alloys • Digital twins, robotic controls, and 3D printing software MDF’s 110,000 ft2 facility in Knoxville, Tennessee, currently houses more than 230 pieces of equipment and 250 staff. Researchers have used these systems to successfully fabricate parts of diverse shapes and sizes, from a 1.3-lb robotic hand to a 5000-lb compression molding tool. Staff at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory work to solve industry’s modern manufacturing challenges. Courtesy of ORNL, U.S. Dept. of Energy. MDF at ORNL develops platform technologies for a range of research and application areas to increase U.S. competitiveness. Courtesy of ORNL, U.S. Dept. of Energy. Over 40,000 people have visited and engaged with the MDF at ORNL, resulting in more than $5.5 billion in economic impact. Courtesy of Carlos Jones/ORNL, U.S. Dept. of Energy.
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