--- title: "ORNL’s mold-free 3D printing method cuts composite fabrication time by 95%" url: https://www.voxelmatters.com/ornls-mold-free-3d-printing-method-cuts-composite-fabrication-time-by-95/ date: 2026-06-18 modified: 2026-06-18 lang: en author: "Joseph Caron-Dawe" description: "Researchers at the US Department of Energy's Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) have developed a hybrid additive manufacturing method that removes the need for molds..." categories: - "3D Printing Processes" tags: - "future" image: https://www.voxelmatters.com/wp-content/uploads/2026/06/ORNL-mold-free-3D-printing-01-640x514.jpg word_count: 363 --- # ORNL’s mold-free 3D printing method cuts composite fabrication time by 95% [Researchers at the US Department of Energy's Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL)](https://www.voxelmatters.directory/company/oak-ridge-national-laboratory/) have developed a hybrid additive manufacturing method that removes the need for molds in composite fabrication, cutting production time by up to 95% and costs by around 90%, compared to conventional mold-based approaches.  The process deposits composite materials directly onto a flexible fabric substrate such as nylon, glass fiber, or resin-infused composite fibers, and builds flat structures that can be folded into three-dimensional forms. An integration layer, typically thermoplastic polyurethane, bonds the fabric base to a reinforcing composite layer, which may include thermoplastic carbon-fiber acrylonitrile butadiene styrene (ABS) or thermoset formulations such as styrene- or epoxy-based resins. [The materials bond at the molecular level](https://www.voxelmatters.com/yokohama-researchers-develop-recyclable-resin-for-high-precision-3d-printing/), producing a single integrated component without finishing or tooling. The method also allows fabrication of objects larger than the printing equipment itself, a characteristic that reduces capital costs and broadens the range of producible geometries. ## Origami as engineering logic The design logic draws on origami principles — the precise folding of flat material into functional three-dimensional geometry — applied to composite structures that merge rigid and flexible elements in a single build. “This pioneering method redefines advanced manufacturing by fusing material science with transformative design principles,” said Steven Guzorek, Lead Researcher and Materials Scientist at Oak Ridge National Laboratory. “By applying origami-inspired principles to hybrid composites, we are improving the efficiency and scalability of large-structure manufacturing and achieving forms unattainable with traditional additive approaches — advancing robust, cost-effective solutions for a broad range of applications.” According to Guzorek, material selection was central to achieving reliable interfacial bonding. “By understanding the materials science, we chose materials that we knew would bond effectively, producing a truly integrated component,” he added. “Our goal is to make this innovation scalable so manufacturers across industries can harness its potential. By broadening access to mold-free hybrid composites, we're empowering manufacturers to explore new design possibilities and unlock entirely new applications for this transformative technology.” [ORNL has filed a patent on the method and is preparing it for future licensing](https://www.voxelmatters.com/ornl-researchers-combine-multiple-3d-printing-extruders/). The research was conducted at the MDF, which is supported by the DOE's Advanced Materials and Manufacturing Technologies Office.