ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 15 Anduril to rapidly progress from concept to complete vehicle to commercialization. Anduril has since partnered with Additive Engineering Solutions— an Ohio-based company founded to leverage BAAM technology—to design, manufacture, and sell hundreds of lowcost, high-quality 3D-printed LDUUVs for use in civilian and military sectors. DEMONSTRATING IMPACT: PEREGRINE BRINGS MANUFACTURING INTO THE FUTURE Researchers at MDF are developing digital manufacturing technologies to help companies of all sizes improve production and quality inspection processes. Such technologies are especially relevant for parts produced for harsh environments and high-risk applications like aerospace or nuclear power generation. Through conversations with multiple companies, MDF researchers realized that part qualification posed a particular challenge for manufacturers using powder bed printers to produce complex components. Due to the nature of the additive manufacturing processes, flaws could occur at any point during printing, forcing most manufacturers to rely on x-ray computed tomography (CT) scans after printing to qualify the parts. To solve this problem, MDF initiated a research and development project leveraging core ORNL expertise in additive manufacturing, materials science, machine learning, and data science to develop a more efficient and cost- effective alternative: an artificial intelligence (AI) software tool called Peregrine that enables real-time process monitoring, visualization, and quality control during printing. This tool offers a cost-effective alternative to expensive characterization equipment using an off-the-shelf camera, a high-powered desktop computer, a custom neural network architecture, and supporting processing algorithms. Peregrine uses AI to search camera images for anomalies identifiable by distinguishing features such as lines, color variations, and texture differences. It analyzes data in situ, continuously checking for uneven distribution of the powder or binding agent, porosity, and other anomalies. In some cases, Peregrine can be used for real-time adjustments to the printing process. Throughout the manufacturing process, Peregrine collects a suite of data that can be used in various ways by manu- facturers to inform ongoing process improvements. Since 2020, this tool has been licensed by more than 40 corporate, academic, and government entities. MDF and partners have demonstrated the software on more than 20 types of powder bed printers using electron beam melting, laser powder bed, and binder jet technologies. Comprehensive Peregrine datasets for representative additive systems are publicly available through the DOE Office of Scientific and Technical Information website. Peregrine is moving manufacturers closer to the “factory of the future,” characterized by energy, time, cost, and material efficiencies gained from self-correcting, automated manu- facturing systems. Ultimately, MDF researchers envision that tools like Peregrine will enable manufacturers to produce born-qualified components suitable even for critical energy and defense applications. To that end, MDF seeks to keep improving Peregrine by correlating detected anomalies with critical material flaws and quantitatively estimating component quality. ENGAGING WITH MDF In summary, a unique public- private partnership model, the Manufacturing Demonstration Facility, has been established to help U.S. industry develop efficient, cost-saving advanced manufacturing technologies, build domestic capacity, and ultimately drive economic growth and supply chain resilience. Over 40,000 people have visited and engaged with the MDF, resulting in more than 280 CRADAs, new industries, and more than $5.5 billion in economic impact, a true innovation ecosystem. Companies of all sizes that manufacture equipment, process materials, produce manufacturing-related software, or integrate energy systems in the U.S. can leverage ORNL’s expertise and MDF’s capabilities. Visit ornl.gov/ content/collaboration or contact Bob Slattery at slatteryrs@ornl.gov to learn more about the MDF Technical Collaboration Program. ~AM&P For more information: Craig Blue, chief manufacturing officer, Oak Ridge National Laboratory, 1 Bethel Valley Rd., Oak Ridge, TN 37830, 865.574.4351, blueca@ornl.gov, ornl.gov. The Peregrine system in operation at MDF. Courtesy of ORNL, U.S. Dept. of Energy. Peregrine monitors and analyzes components made with powder bed printers to assess quality and detect defects without the need for expensive characterization equipment. Courtesy of Vincent Paquit/ ORNL, U.S. Dept. of Energy.
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