Adaptive 3D Printed Micro-Hydropower for Resilient Grids: Digital-to-Deployment Framework

We propose to enhance the resilience of the U.S. electricity grid by enabling the rapid, adaptive, and on-demand manufacturing of site-specific micro-to-small hydropower systems for low-head dams. This approach directly addresses the nation's untapped 85,000+ non-powered dams (NPDs) and low-head sites for resilient, distributed energy assets. Specifically, the Department of Energy (DOE) has identified 51,000 dams as potential microhydro sites, a resource that largely remains undeveloped because a majority of such sites lack a cost-effective solution for conversion.

Hydropower systems, especially small-scale ones, are vulnerable to outages from long-term precipitation change, floods, and damage to a turbine from debris which can lead to months or even years of downtime due to the long lead times for conventionally manufactured replacement parts. Moreover, hydrological conditions are not static. For example, upstream land use, long-term weather change, seasonal variations cause changes in water flow rates over time. We propose a solution that moves beyond static, one-size-fits-all hardware to an adaptive system that can adapt to and recover rapidly from disruptions.

Near-Term Opportunity: We propose to establish a complete digital-to-deployment (D2D) framework that leverages an award-winning collaboration between Oak Ridge National Laboratory (ORNL) and Cadens Hydro. This framework integrates high-performance computing, advanced manufacturing, and a robust domestic supply chain to deliver cost-effective, adaptive, and resilient hydropower systems. This effort addresses both components of the LCOE (cost and revenue) in a potentially significant manner. The generation portion of the LCOE is improved by designing turbines tailored for site specific conditions while cost is kept low with Additive Manufacturing (AM).

Proven record of collaboration: ORNL and Cadens proved the viability of this approach. Using ORNL's BAAM system, we successfully manufactured large-scale, end-use hydropower components (including conveyance: draft tubes, thimble adapters, and runner housing molds) from cost-effective, durable composites. These 3D-printed components have been in continuous operation at the Cadens Rome Mill Ultra-Low Head Test Facility for over five years without a single 3D-printed component failing.

WPTO Recognition: This approach was recognized by the Water Power Technologies Office as the top-placing winner of the Innovations in Advanced Manufacturing for Hydropower (I AM Hydro) Prize.

Five-Step Solution: An Adaptive Manufacturing Framework
1. Create a Digital Library for Adaptive Design: We will leverage ORNL's HPC resources to dramatically expand an existing design library.
2. On-Demand, Site-Specific Turbine Manufacturing: We will develop an on-demand manufacturing process and demonstrate the capability to select an optimal, site-specific turbine design from the digital library, manufacture it using 3D printing, and have it ready for shipment in days.
3. Field Deployment: We will select two to three non-powered dam or low-head sites from Cadens' pipeline.
4. Quantify Success Measure: We will continuously monitor the demonstration sites to gather the data on performance and resilience.
5. Build a Domestic Supply Chain: ORNL will connect Cadens with our established network of industry partners, including material suppliers (e.g., Techmer, Airtech) and manufacturing service providers to create a distributed manufacturing network.

Success Measure: We will quantify success against multiple factors.
- Adaptation: >15% increase in Annual Energy Production (AEP) at a site with variable hydrology through installing an adaptively-designed AM turbine.
- Recovery: > 80% reduction in lead time for a critical turbine component.
- Cost: > 40% cost reduction as compared to the cast and machined equivalents.
- Durability: >10,000 cumulative operational hours across the new demonstration sites.