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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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This report highlights some of our overarching successes and quantifies the impacts achieved by this program over five years and two presidential administrations. We are proud to say that American-Made has come a long way since its inception, but there is more work to be done. We hope you will not only celebrate our shared successes, but also join us to lay the groundwork for the next stages of the clean energy revolution.
To evaluate the potential of Sonic Wafering(TM), a new manufacturing method that may lower the cost of high-efficiency photovoltaic materials. This work is to be conducted in support of the Department of Energy’s American Made Challenges Solar Prize.
This report documents the technical assistance provided to Orison as part of the American-Made Challenges Round 2 Voucher: Orison Enables Solar project. A testbed was developed and used to demonstrate, using modeling and simulation, the capability of controlled behind-the-meter energy storage to (1) reduce net load variability caused by appliances and distributed generation and (2) enable customers to respond to the time-of-use pricing. We demonstrate that load leveling can shave peak loads or limit solar photovoltaic export and that load shifting enables customers to reduce load during “peak” pricing intervals. In the scenarios that we simulated, load leveling was effective up to the charging and discharging limits of the storage systems and the effectiveness of load shifting was a function of the energy capacity of the storage systems. This report describes the co-simulation testbed and the scenarios simulated, including controller setup and simulation results. Considerations for a multi-objective controller are also discussed.
This work was conducted in support of the American Made Geothermal Prize. The following data summary report presents the testing conducted at Sandia National Labs to validate the performance of the Ultra-High Temperature Seismic Tool for Geothermal Wells. The goal of the testing was to measure the sensitivity of the device to seismic vibrations and reliability of the instrument at elevated temperatures. To this end, two tests were conducted: 1) Ambient Temperature Seismic Testing, which measured the response of the tool to a sweep of frequencies from 1 to 1000 Hz, and 2) Elevated Temperature Survivability Testing which measured the voltage response of the device at 225°C over a month-long testing window. The details of the testing methodology and summary of the tests are presented herein.
The goal of this prize is to establish a pathway to cost-effective domestic manufacture and deployment of gigawatt-scale floating wind farms in U.S. waters. Toward realization of that goal, the prize will: (1) incentivize and support further development of technically and economically viable floating wind platform structures that can support 12-MW-rated or larger wind turbines in water depths over 40 meters. (2) incentivize the creation of a supply chain that will enable domestic on-site manufacturing of floating offshore wind farm components utilizing a skilled and trained workforce. (3) promote awareness of the importance and principles of inclusion and environmental justice.
Renewance is a Phase II winner of the U.S. Department of Energy Lithium-ion Battery Recycling Prize. The Prize is designed to incentivize American entrepreneurs to develop and demonstrate processes that, when scaled, have the potential to profitably capture 90% of all discarded or spent lithium-based batteries (LIB) in the Unites States for eventual recovery of key materials for re-introductions into the U.S. supply chain. The objective of this work is to enable a more efficient evaluation of battery sources for second life applications prior to ultimately being recycled, through evaluation of chemistry characteristics, projected battery lifetime, and application history. This work will develop the capability to identify groups of batteries that may be useful for second life and reduce the cost of end-of-life (EOL) LIB evaluation and repurposing. To meet the objective, NREL will use existing and new data to create a refined algorithm that could be used to evaluate batches of batteries for potential reuse based on manufacturing date and historical use characteristics. Based on current battery market prices and compiled literature data, a starting-point estimate of the market value of the batteries for reuse based on expected lifetime will be included in the algorithm. With the projected surge in LIB demand, battery second life is a new area ripe for development and investment from companies like Renewance. With so few large format batteries reaching EOL to date, this is a new market with a variety of areas for optimization and adding value. This work with Renewance is an example of how existing expertise in battery degradation at NREL can be used to reduce the cost of shifting a battery into a second life application. With these cost reductions, this work is also facilitating the development of a battery circular economy in the United States. A robust circular economy can maximize the utilization of critical metals demanded by battery technology such as nickel and cobalt while also reducing the costs of batteries in the marketplace for the many end-uses needed for the green energy transition. The supply of these metals is limited, and we face a supply chain shortage both domestically and globally unless we can ensure they are being used to their maximum potential. This research can improve the economics of a battery circular economy to make it a more likely path for EOL batteries with critical metals. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.
Evaluate membrane technologies synergistic with high-temperature hydrogen-rich syngas production from biomass to determine the type and integration thereof that is most cost-effective.
The purpose of this project was to demonstrate how granular time series data and automated data transformation, and impact assessment tools could speed interconnection approvals for distributed energy resource projects of various types and sizes. Types included community solar, rooftop solar, and EV charging projects. Using software routines to automate the transformation of data (e.g. GIS) to a network database and power flow model then applying scenarios to create hourly (8760) hosting capacity values and voltage and thermal impacts for specific projects, we were able to demonstrate the feasibility of quickly assembling and analyzing key utility data sets for interconnection purposes. The outcomes of this effort will become the foundation for future work that will enhance and encapsulate the software components developed as part of this project, into web services (e.g. APIs) that can be integrated into queue management systems and automate interconnection screening processes.
This report summarizes the Phase 2 achievements of the Wind Turbine Materials Recycling Prize project led by Critical Materials Recycling (CMR) in partnership with Ames National Laboratory. The team demonstrated the technical feasibility and economic viability of recovering and reusing rare-earth Nd-Fe-B magnets from end-of-life (EOL) wind turbine generators. Through mechanical disassembly, demagnetization, and precision processing, magnets were harvested and characterized to assess structural, compositional, and magnetic properties. Results showed that recovered magnets performed on par with commercial-grade counterparts, enabling their integration into actuator and motor prototypes without redesign. System-level modeling and finite-element simulations validated operational performance, while Life Cycle Cost (LCC) analysis revealed up to 20% material cost savings and 2–3% reductions in overall motor system costs. Life Cycle Assessment (LCA) further confirmed substantial environmental benefits, including a ~94% reduction in global warming potential relative to virgin magnet production. The project’s success was enabled by a tightly integrated partnership between industry and national lab experts, illustrating a viable path for domestic magnet-to-magnet recycling. These findings support a scalable, circular solution for rare-earth material recovery, reducing dependence on imported critical minerals and advancing sustainable clean energy technologies.
Purdue University plans to use microorganisms to extract Ga from GaN/GaAs chips. This method is aimed at replacing traditional hydrometallurgy.
This presentation, "Evolution of Federal Incentives and Requirements," explores the development and impact of federal cybersecurity regulations, tax credits, and domestic content requirements on the energy sector. It covers key legislation such as the ARRA of 2009, IIJA, and IRA, and their implications for grid modernization, manufacturing, and deployment of energy technologies. The presentation also addresses definitions and restrictions related to Foreign Entities of Concern (FEOC) and their impact on federal procurement. Additionally, it introduces the DOE's cybersecurity framework for energy supply chains and practical actions for compliance planning.
Foreign Entity of Concern (FEOC) restrictions in the One Big Beautiful Bill Act (OBBB) represent the latest evolution of a multi-year legislative trajectory responding to national security concerns about foreign control – and particularly FEOC control – of energy infrastructure. Beginning with Executive Order 14017 (February 2021), which initiated comprehensive federal review of critical supply chain vulnerabilities in semiconductors, battery energy storage systems, and critical minerals, policymakers have progressively expanded restrictions on foreign participation. The National Defense Authorization Act (NDAA) 2019 established precedent for component-level prohibitions on foreign information and communications technology procurement, while NDAA 2024 extended these restrictions to six major People’s Republic of China (PRC) battery manufacturers. Complementary measures such as the Build America, Buy America (BABA) Act and the Infrastructure Investment and Jobs Act (IIJA) introduced domestic content thresholds and FEOC eligibility criteria for federal funding programs. The Inflation Reduction Act (IRA) 2022 further operationalized FEOC restrictions through electric vehicle tax credit requirements, creating a scalable framework for excluding foreign-controlled components. Recent executive actions and state-level policies have reinforced this trajectory, reflecting sustained alignment across federal and state governments. Collectively, these developments demonstrate a bipartisan policy approach that pairs incentives for advanced energy deployment with safeguards designed to prevent subsidizing adversaries or entities that present foreign-sourcing risk.
In 2018, the U.S. Department of Energy's Solar Energy Technologies Office and the National Renewable Energy Laboratory set out to develop a repeatable, predictable prize model (the American-Made Challenges) and an entrepreneurial innovation network (the American-Made Network) to support participants along their innovation journeys. This began with the launch of the Solar Prize. Five years and six rounds later, the Solar Prize is the longest-standing competition of the American-Made Challenges. It has awarded $\$20.1$ million in cash prizes and $\$5.5$ million in technical support vouchers to 140 teams across all aspects of the solar industry. By sharing the outputs of the prize, we hope that our lessons learned will help continue to build the clean tech entrepreneurship support ecosystem.
In 2018, the U.S. Department of Energy's Solar Energy Technologies Office and the National Renewable Energy Laboratory set out to develop a repeatable, predictable prize model with the American-Made Challenges. A new model launched by the Solar Energy Technologies Office in March 2021 was the American-Made Perovskite Startup Prize. This new prize aimed to accelerate the growth of the domestic perovskite industry and support the rapid development of solar cells and modules that use perovskite materials. By sharing the outputs of the prize, we hope that our lessons learned will help continue to build the clean tech entrepreneurship support ecosystem and influence how a successful prize design can be achieved.
The American Made Solar Prize is a prize competition from the U.S. Department of Energy (DOE) that is designed to revitalize U.S. solar manufacturing. The competition aims to support the growth of U.S. solar manufacturing and reenergize American energy innovation by tapping into American's competitive spirit and the nation's unparalleled innovation ecosystem leveraging national labs, incubators, facilities and more.
The American-Made Solar Forecasting Prize, Net Load Forecasting Prize, and Data-Driven Distribution (3D) Solar Visibility Prize is a multimillion-dollar prize competition designed to energize U.S. solar innovation through a series of contests that accelerate the entrepreneurial process from years to months. The activities incentivized by these three prizes will support the governmentwide approach to increase American energy dominance by promoting innovation and early deployment of energy technologies, resulting in wider adoption, which is critical for secure, affordable, and reliable solar energy.
American-Made team and network partners discuss the new opportunities to support innovation and foster research pathways through prizes, voucher programs, and network development.
Millions of Americans have experienced the benefits of transitioning to solar, such as money saved on electricity bills and reduced environmental impact. However, many households have been overlooked and left out of this energy transition due to limited funds, low credit scores, language barriers, or lack of solar adoption from neighbors and other community members. Leading organizations have recognized this gap in communications and have started to target more diverse audiences in their solar marketing campaigns. This project outlines three years of American-Made prize funding, recognizing solar industry communications campaigns that demonstrate excellence in strategic, effective, and meaningful communication to diverse audiences across digital, video, marketing, mobile, print, social media, and more.