Some of the toughest challenges in American manufacturing are being solved without ever stepping onto a factory floor. Inside supercomputers, scientists are modeling systems too complex, costly or time-consuming to test in the real world.
In the latest episode of the Big Ideas Lab podcast, Lawrence Livermore National Laboratory (LLNL) spotlights the High-Performance Computing for Energy Innovation (HPC4EI) program, an LLNL-managed U.S. Department of Energy (DOE) initiative that connects DOE national laboratory expertise with private industry to improve energy efficiency, streamline processes and strengthen domestic manufacturing. Listen on Apple or Spotify.
The episode examines how HPC4EI leverages DOE's high-performance computing capabilities to help companies address challenges in critical sectors of the U.S. economy. The program pairs industry partners with scientists across the DOE national laboratory system to translate complex operational challenges into computational problems. By simulating physical systems - from heat transfer and fluid dynamics to materials behavior - researchers can identify solutions before they are deployed in real-world environments.
"The bottom line is we're using computing to solve real-world problems," said Brandon Wood, LLNL HPC4EI project lead.
The results demonstrate the impact of applying advanced modeling to industrial processes. Projects have improved efficiency in automotive systems, reduced energy demand in manufacturing and optimized material performance. In one case, modeling industrial paint drying led to a 30 percent reduction in energy use.
Heavy industry accounts for nearly a third of U.S. energy consumption, meaning even modest improvements can deliver significant reductions in energy use and emissions while improving economic competitiveness. Since its launch, HPC4EI has supported over 200 projects across 12 national laboratories.
"We've worked with over 100 companies at this point - from the startups trying to get a new product off the ground to huge companies that already do some computational physics - and we help bring them to the next level," said Aaron Fisher, HPC4EI director.
The episode also highlights how DOE's investment in computational science enables more than individual project outcomes. By fostering long-term collaborations between industry and the national labs, the program builds a foundation for sustained innovation.
Advances in AI are further amplifying these capabilities. AI and machine learning models are beginning to replicate complex simulations in seconds, allowing companies to rapidly explore design options and optimize processes. In one example, an AI-driven model reduced simulation time from weeks to near real time in a glass-manufacturing application, saving more than $1 million annually while reducing carbon emissions.
"AI has been evolving rapidly in the past few years, and the capability of AI keeps increasing at a speed that we can't even imagine," said Yeping Hu, LLNL HPC4EI project lead.
The HPC4EI program also strengthens DOE's broader mission. Computational tools developed and refined through HPC4EI contribute to national security applications, reinforcing the value of cross-sector collaboration. As the episode highlights, HPC4EI is expanding what can be achieved through computation, enabling scientists and engineers to tackle increasingly complex challenges across energy and manufacturing.
Listen to the latest episode of Big Ideas Lab to learn how the HPC4EI program is translating advanced computing into measurable impact for U.S. industry and expanding what's possible for American manufacturing: listen on Apple or Spotify.
