Cover and back images are courtesy of Oak Ridge National Laboratory. Sidebar images are courtesy of Oak Ridge National Laboratory and Argonne National Laboratory and are reprinted with permission from the American Chemical Society and Springer/Nature. Factual Document for the Basic Energy Sciences Basic Research Needs Workshop for Transformative Manufacturing Chair – Cynthia Jenks, Argonne National Laboratory Co-Chair – Ho Nyung Lee, Oak Ridge National Laboratory Co-Chair – Jennifer Lewis, Harvard University Panos Datskos, National Renewable Energy Laboratory; Joe Cresko, Department of Energy; William Morrow, Lawrence Berkeley National Laboratory; Greg Krumdick, Argonne National Laboratory with contributions from T. Kaarsberg (DOE) J. Spangenberger (Argonne) M. Klembara (DOE) M. Stan (Argonne) K. R. Kort (DOE) D. Singh (Argonne) G. J. Leong (DOE) V. Srinivasan (Argonne) T. Miller (DOE) M. Wang (Argonne) K. Peretti (DOE) M. Wu (Argonne) D. Berry (NREL) Y. Zhang (Argonne) A. Burrell (NREL) A. Naskar (ORNL) A. Carpenter (NREL) V. Kunc (ORNL) S. Hammond (NREL) T. Kurfess (ORNL) M. Ringer (NREL) N. Lavrik (ORNL) M. Ulsh (NREL) L. Love (ORNL) S. Seetharaman (NREL/CSM) S. U. Nimbalkar (ORNL) S. Chaudhuri (Argonne) V. Paquit (ORNL) J. Chen (Argonne) M. Theodore (ORNL) S. Darling (Argonne) S. Smith (ORNL) M. U. Demirtas (Argonne) C. Tsouris (ORNL) J. W. Elam (Argonne) J. Turner (ORNL) D. Graziano (Argonne) D. Wood (ORNL) A. Harris (Argonne) V. Battaglia (LBNL) N. Iloeje (Argonne) P. Rao (LBNL) T. Krause (Argonne) A. Weber (LBNL) J.Kopasz (Argonne) P. Randall Schunk (SNL) C. Negri (Argonne) J. Greenblatt (Emerging Future, LLC) K. Pupek (Argonne) Abbreviations, Acronyms, and Initialisms 2D two-dimensional 3D three-dimensional 5G fifth generation ACSM atomic or close-to-atomic scale manufacturing ACGIH American Conference of Governmental Industrial Hygienists AEO Annual Energy Outlook AFM atomic force microscopy AHSS advanced high-strength steel AI/ML/DL artificial intelligence/machine learning/deep learning ALD atomic layer deposition ALE atomic layer etching AM additive manufacturing AMO DOE Advanced Manufacturing Office Argonne Argonne National Laboratory ANSI American National Standards Institute APS Advanced Photon Source BCE before common era Bgal/d billion gallons per day BPP bipolar plate BOF basic oxygen furnace Btu British thermal unit CaCO3 limestone CAD computer-assisted design CALPHAD CALculation of PHAse Diagrams CCS carbon capture and storage CF carbon fiber CFL compact fluorescent lighting CFRP carbon fiber–reinforced polymer CFTF Carbon Fiber Technology Facility CM critical materials CNC computer numerical control CO2 carbon dioxide CSE coal sourced electricity CSM Colorado School of Mines iv DL deep learning DOE US Department of Energy DPN dip pen nanolithography EBL electron beam lithography EES electrochemical energy storage EHS Environment, Health and Safety EIA US Energy Information Administration ELB electron beam lithography ESH environmental, safety, and health EU European Union EV electric vehicle FC fuel cell Fe iron FET field effect transistors FDP fossil resource depletion potential GDL gas diffusion layer GHG greenhouse gas Gt gigatons GWP global warming potential HDL hydrogen depassivation lithography HPC high-performance computing HTP human toxicity potential IACMI Institute for Advanced Composites Manufacturing Innovation IBC international building code ICEV internal combustion engine vehicle IR infrared IoT internet of things kHz kilohertz LBNL Lawrence Berkeley National Laboratory LCOE levelized cost of electricity LED light-emitting diodes Li lithium Li-ion lithium-ion LIB lithium-ion battery LiFePO4 lithium iron phosphate LiNCM lithium nickel cobalt manganese v MCMC Monte Carlo Markov Chain MDF Manufacturing Demonstration Facility MDP mineral resource depletion potential MEA membrane electrode assembly ML machine learning MLD molecular layer deposition MT metric ton NDE nondestructive evaluation NdFeB neodymium-iron-boron NFPA National Fire Protection Association NG natural gas sourced electricity NIOSH National Institute for Occupational Safety and Health NREL National Renewable Energy Laboratory OLED organic light-emitting diode ORNL Oak Ridge National Laboratory OSHA Occupational Safety and Health Administration PAN polyacrylonitrile PCM phase change material PEMFC polymer electrolyte membrane fuel cell PFE printed flexible electronics PGM platinum-group metal PI process intensification PM particulate matter Pt platinum PV photovoltaic quad quadrillion R&D research and development R2R roll-to-roll Re-X reduce, reuse, remanufacture, and recycle REE rare-earth elements RFID radio frequency identification antenna SAXS small-angle x-ray scattering SB scanning beam SCM supplementary cementitious material SDS safety data sheet Si silicon vi SI system integration SNL Sandia National Laboratories SP scanning probe SSB solid-state battery STM scanning tunneling microscopy US United States WHP waste heat-to-power WHR waste-heat recovery X-T-P composition, temperature, and pressure vii Table of Contents List of Figures .......................................................................................................................................................... x List of Tables ........................................................................................................................................................... xi 1 Manufacturing Background and Overview ..................................................................................................... 1 1.1 Introduction ................................................................................................................................................ 1 1.2 Role of Manufacturing in the US Economy .............................................................................................. 3 1.3 Energy and Environmental Impact of Manufacturing ............................................................................... 4 1.3.1 Intensity Metrics and Definitions ................................................................................................. 4 1.3.2 Energy Use and Intensity .............................................................................................................. 5 1.3.3 Material Use and Intensity .......................................................................................................... 12 1.3.4 Environmental Emissions and Intensity ..................................................................................... 14 1.3.5 Water Use and Intensity .............................................................................................................. 15 2 Advanced Manufacturing State of the Art .................................................................................................... 19 2.1 Digital Manufacturing .............................................................................................................................. 19 2.1.1 Cloud/Fog/Edge Capabilities and Utilization ............................................................................. 19 2.1.2 Data Structure and Architecture Needs....................................................................................... 20 2.1.3 Infrastructure Requirements ....................................................................................................... 21 2.1.4 Cybersecurity .............................................................................................................................. 22 2.1.5 Digital Twin/Data Analytics/Advanced Modeling ..................................................................... 22 2.1.6 Low-Cost and Smart Sensor Development ................................................................................. 22 2.1.7 Industry 4.0 ................................................................................................................................. 23 2.1.8 Relevance of Industry 4.0 to DOE’s Mission ............................................................................. 24 2.2 Example Manufacturing Processes and Use Cases .................................................................................. 25 2.2.1 Additive Manufacturing .............................................................................................................. 25 2.2.2 Chemical Manufacturing/PI/Decentralization ............................................................................ 26 2.2.3 Roll-to-Roll Manufacturing ........................................................................................................ 29 2.2.4 Composite Materials Manufacturing .......................................................................................... 36 2.2.5 Energy Storage Manufacturing ................................................................................................... 48 2.2.6 Metal Processing and Manufacturing ......................................................................................... 57 2.2.7 Cement Production ..................................................................................................................... 59 2.2.8 Atomically Precise Manufacturing ............................................................................................. 65 3 Resilient and Sustainable Manufacturing ..................................................................................................... 70 3.1 Integrated Manufacturing Processes 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