STAR interview: reshaping tomorrow through additive manufacturing of energy materials

Wednesday 21 January 2026

In this STAR interview, we speak to Davoud Jafari of the Faculty of Engineering Technology (ET). STAR is an acronym for (S)ituation, (T)asks, (A)ctions, (R)esults. We also have many “star” colleagues at UT with interesting stories to tell. Davoud Jafari applies the physics of fabrication and thermal engineering to synthesise, characterise, and incorporate innovative materials into next-generation energy conversion and storage systems.

Situation

What is/was the situation (S) of your research/initiative?

At the core of my research lies a shared motivation: to contribute to a more sustainable future by rethinking the design and application of energy technologies. The central challenge is to develop energy systems that are cleaner, smarter, and more efficient, starting at the level of materials innovation. This initiative began with a fundamental question: can materials be engineered not only to improve existing technologies but also to enable novel methods for energy storage and conversion? This inquiry led to a dual approach combining a fundamental understanding of material behaviour with practical development, particularly through additive manufacturing. By integrating principles from thermal engineering, materials science, and fabrication technologies, we develop and evaluate advanced materials for real-world energy applications. These materials include smart systems responsive to heat or magnetic fields, as well as multi-material and composite structures optimised for heat transfer, chemical reactivity, and electrochemical performance.

“A key challenge, and a central focus of my research, is achieving precise control over how materials conduct heat and electricity, facilitate electron or chemical reactions, and control fluid transport. This requires tuning functional properties to meet specific application requirements.”

Our work spans porous materials, metal–semiconductor composites, and shape-memory systems, with the overarching goal of transitioning laboratory-scale innovations into scalable, practical technologies. This combination of fundamental research and applied engineering defines the context of the initiative: Additive Manufacturing Solutions for Energy Materials.

Tasks

What tasks (T) were or are you currently working on?

On the education side, I have been teaching both undergraduate and graduate students, as well as delivering professional training to PhD students. One example of a module I teach is Fluid Mechanics & Heat Transfer. My teaching approach goes beyond covering the mathematical and physical foundations of the subject; it also offers a broader perspective on the complexities of experimental and numerical heat transfer, connecting them to today’s global environmental and societal challenges. This approach prepares students for their professional careers by combining scientific rigour with an understanding of ethics, business, and societal impact, which are essential for success as professional engineers.

In research, I have launched a new line of work responding to the evolving needs of the energy sector, particularly the demand for innovative, cost-effective, scalable, and flexible manufacturing strategies for emerging high-tech materials. I focus on additive manufacturing solutions for energy materials, aiming to accelerate the practical deployment of transformative energy technologies. This research is part of a broader initiative to optimise system performance through surface and interface functionalization.

My team and I apply core principles at the intersection of thermal, electrochemical, and thermochemical engineering, materials science, and fabrication physics. Our key tasks include the design, synthesis, characterisation, and simulation of novel materials. Main application areas include: thermal management, electrochemical systems (e.g., batteries and fuel cells), and thermochemical systems. This integrated approach supports the development of energy materials and systems that meet the performance, scalability, and sustainability requirements of future technologies.

Actions

What actions (A) are you working on, and who is involved?

Our research focuses on developing advanced solutions across a broad spectrum of application domains, including thermal management, energy storage and conversion (batteries, hydrogen, thermochemical systems), and smart components for electrochemical and thermomechanical applications. We adopt a multi-disciplinary and multi-dimensional approach, balancing material functionality, process scalability, and system efficiency. This approach necessitates a detailed understanding of the interactions among material properties, processing techniques such as additive manufacturing, system architecture, and operational conditions.

A principal objective is to generate solutions that are not only scientifically innovative but also broadly transferable, suitable for integration into both large-scale industrial systems and small to medium enterprises. By emphasising innovation alongside practical applicability, we aim to achieve meaningful technological and societal impact.

Our activities are supported by a dedicated research team comprising over ten PhD students and postdoctoral researchers, each specialising in distinct aspects of materials development and process engineering. Collectively, I contribute to and coordinate more than ten ongoing EU-funded projects, including ThermoDust, STORDAGE, IPCE-MISD, BEAM-TMD, COMET, SpaceFuse, PrintFuel, WISH, Smart Skin, and SuperCaloric. These projects facilitate the advancement and deployment of state-of-the-art materials and manufacturing technologies and foster strong collaborations with both academic and industrial partners.

Results

What results (R) do you hope to achieve, and how will society (or UT organisation) perceive them?
Together with my research team, I aim to deliver advanced materials and manufacturing solutions that significantly improve the efficiency, sustainability, and scalability of energy technologies. Through the development of innovative materials optimised by additive manufacturing and supported by modelling tools, we anticipate making significant progress in energy conversion, storage, and thermal management systems that are applicable in real-world environments. We actively collaborate with academic and industrial partners and engage in multiple EU-funded projects, ensuring that our outcomes align with practical requirements and industry standards.

The anticipated results will facilitate cleaner, smarter, and more adaptable energy systems, thereby contributing to the global transition toward sustainable energy and reduced environmental impact. From a societal perspective, these advancements will support the deployment of transformative energy technologies that are economically viable and environmentally responsible, promoting enhanced energy security, lower carbon emissions, and the adoption of circular economy principles within manufacturing and energy sectors.