Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a new hybrid 3D-printing process that combines origami-inspired design with advanced composite materials. The mould-free method transforms flat printed components into three-dimensional structures. As a result, manufacturers can produce lightweight parts faster, more flexibly and at a lower cost.

The technology combines flexible and rigid materials within a single component. This approach enables complex geometries that traditional mould-based production cannot easily achieve.

Hybrid Materials Form Strong Foldable Structures

Traditional composite manufacturing produces strong and durable parts. However, it often requires expensive moulds, long lead times and extensive finishing. ORNL’s new method removes these limitations by printing directly onto flexible fabric substrates.

The process starts with a high-strength fabric, such as nylon, glass fibre or resin-infused composite fibres. Next, the printer deposits a bonding layer, typically thermoplastic polyurethane (TPU). This layer ensures strong adhesion between the fabric and the reinforcing material. Finally, the system prints structural composite materials onto the surface.

Manufacturers can tailor the reinforcement to the application. Thermoplastic carbon fibre-reinforced acrylonitrile butadiene styrene (ABS) offers lightweight structural performance. Epoxy- or styrene-based thermoset resins provide greater stiffness, dimensional stability and durability. By carefully selecting compatible materials, the researchers created molecular bonds between the layers. These bonds produce a fully integrated composite component.

Lead researcher Steven Guzorek explained that material compatibility played a crucial role in achieving a strong and reliable bond.

Faster Production With Lower Costs

The mould-free process also delivers major production benefits. Manufacturers no longer need dedicated tooling or mould storage. Instead, they can print flat components directly onto sheet materials and fold them into their final shape afterwards.

In demonstration trials, the researchers reduced fabrication time by 95% and production costs by 90% for a unique component compared with conventional mould-based composite manufacturing. The method also makes it possible to produce structures that are larger than the printer itself by folding flat printed sections into three-dimensional forms.

These advantages reduce production costs while supporting both thermoplastic and thermoset composite systems.

Preparing The Technology For Industry

ORNL believes the technology can make advanced composite manufacturing more accessible across multiple industries. It also opens new possibilities for lightweight structural design and rapid manufacturing. The laboratory has filed a patent and is preparing the process for future licensing.

The team carried out the research at ORNL’s Manufacturing Demonstration Facility with support from the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office.

Source: Oak Ridge National Laboratory
Images: Andrew Sproles / ORNL, U.S. Dept. of Energy