Uploaded December 2025 | Updated September 2026, 1 week ago
Additive Engineering Solutions (AES), an Ohio-based company specializing in large-format polymer 3D printing, traces its origin to foundational work at the U.S. Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory. The collaboration began with early demonstrations of big area additive manufacturing (BAAM) and has grown into a long-term partnership that is expanding U.S. manufacturing capabilities and strengthening regional industrial networks.
Working with ORNL’s MDF, founders Austin Schmidt and Andrew Bader have advanced the use of BAAM systems and refined the Slicer software developed at ORNL. Their ongoing collaboration helps industry accelerate large-scale printing techniques, optimize tooling design, and explore new manufacturing applications across aerospace, defense, and construction.
In this video, learn more about:
· How AES uses large-format polymer 3D printing to produce tooling and components at industrial scale
· How ORNL’s advanced manufacturing ecosystem supports companies developing new processes and software innovations
· How Slicer software guides the geometry, toolpaths, and precision of BAAM printing
· How regional collaborations in Ohio are strengthening American manufacturing capabilities
About the collaboration
AES launched after early work with MDF engineers revealed a gap in commercial access to large-format polymer printing. Through continued engagement with ORNL experts, AES has refined print parameters, explored new polymer systems, and helped inform next-generation software capabilities.
The MDF’s collaborative model connects industry partners with researchers, suppliers, and technology developers, enabling faster testing cycles and accelerating advanced manufacturing solutions.
This work reflects ORNL’s commitment to strengthening U.S. competitiveness through breakthroughs in manufacturing research, materials science, and production technologies. The MDF, supported by the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office, serves as a nationwide consortium designed to innovate, inspire, and catalyze transformative manufacturing advancements.
The C4 Partnering Model
MDF is the model for DOE’s national laboratory system’s C4 Partnering Model—focused on increasing cross-sector collaboration, accelerating technology development, and building strong regional manufacturing ecosystems. Learn more about C4 partnering opportunities across the United States at sandia.gov/c4/.
ORNL is using #BigScience to make a big impact. Learn more: ornl.gov/bigscience
Additive Engineering Solutions (AES), an Ohio-based company specializing in large-format polymer 3D printing, traces its origin to foundational work at the U.S. Department of Energy’s Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory. The collaboration began with early demonstrations of big area additive manufacturing (BAAM) and has grown into a long-term partnership that is expanding U.S. manufacturing capabilities and strengthening regional industrial networks.
Working with ORNL’s MDF, founders Austin Schmidt and Andrew Bader have advanced the use of BAAM systems and refined the Slicer software developed at ORNL. Their ongoing collaboration helps industry accelerate large-scale printing techniques, optimize tooling design, and explore new manufacturing applications across aerospace, defense, and construction.
In this video, learn more about:
· How AES uses large-format polymer 3D printing to produce tooling and components at industrial scale
· How ORNL’s advanced manufacturing ecosystem supports companies developing new processes and software innovations
· How Slicer software guides the geometry, toolpaths, and precision of BAAM printing
· How regional collaborations in Ohio are strengthening American manufacturing capabilities
About the collaboration
AES launched after early work with MDF engineers revealed a gap in commercial access to large-format polymer printing. Through continued engagement with ORNL experts, AES has refined print parameters, explored new polymer systems, and helped inform next-generation software capabilities.
The MDF’s collaborative model connects industry partners with researchers, suppliers, and technology developers, enabling faster testing cycles and accelerating advanced manufacturing solutions.
This work reflects ORNL’s commitment to strengthening U.S. competitiveness through breakthroughs in manufacturing research, materials science, and production technologies. The MDF, supported by the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office, serves as a nationwide consortium designed to innovate, inspire, and catalyze transformative manufacturing advancements.
The C4 Partnering Model
MDF is the model for DOE’s national laboratory system’s C4 Partnering Model—focused on increasing cross-sector collaboration, accelerating technology development, and building strong regional manufacturing ecosystems. Learn more about C4 partnering opportunities across the United States at sandia.gov/c4/.
ORNL is using #BigScience to make a big impact. Learn more: ornl.gov/bigscience
