Unlocking Neutron Science: ORNL’s ‘Frankenstein Design’ for 3D Printed Collimators

The article discusses how scientists at Oak Ridge National Laboratory (ORNL) utilized a “Frankenstein design” approach to overcome challenges in 3D printing neutron collimators for experiments. Collimators are crucial in neutron scattering experiments to filter out unwanted neutrons and improve data accuracy. The traditional method of printing collimators as one-piece structures proved impractical due to scaling issues and precision limitations.

The team adopted a novel approach, printing multiple smaller parts and assembling them manually to form the complete collimator. This strategy minimized material contraction issues during printing, ensuring uniform cooling and reducing the risk of cracking. Additionally, the design incorporated alternate-blade configurations to optimize performance and mitigate alignment sensitivities.

Advanced computational simulations were used to refine the design, enabling direct production without further engineering. The 3D printed collimator was tested on the Spallation Neutron and Pressure beamline, demonstrating increased sample signal and validating the concept’s feasibility.

The study underscores the importance of precision manufacturing and alignment in neutron scattering instrumentation. By combining modeling with advanced manufacturing techniques, the research presents a new approach to customizing collimators and advancing neutron science.

The article is accompanied by images illustrating the “Frankenstein design” collimator and the research team’s collaboration.