Printing the Future of Energy: Inside UTEP’s Estrella Lab

Maurel and Martinez’s partnership demonstrates their complementary skills. Maurel, who studied 3D printed lithium-ion batteries for his doctoral research in France, joined UTEP as a Fulbright Visiting Scholar, bringing with him this groundbreaking concept. Martinez added extensive expertise in electrochemistry, and together they launched the Estrella Lab, a fusion of Energy Storage and Electronics 3D Printing Laboratories. Their shared goal was clear: develop batteries that are not only more powerful and eco-friendly but also tailored to real-world needs.

Through a NASA-funded project, the team is developing the capability to remotely print 3D sodium-ion batteries on the Moon and Mars, using local regolith, loose rock fragments, interstellar dust, and debris as raw materials. By eliminating the need for expensive interplanetary transport, this work envisions a future in which robots and 3D printers prepare energy systems before astronauts even arrive on distant planets. Components made in El Paso will soon be tested aboard the International Space Station to evaluate their ability to withstand radiation and extreme environments.

Closer to home, the lab’s discoveries are expanding opportunities for students. A new collaboration with Texas A&M, supported by the National Science Foundation (NSF), will provide undergraduates with hands-on experience in designing multifunctional batteries that transition from flexible to structural systems through 3D printing. Each year, eight students will train through this program, splitting their time between El Paso and College Station. “Research is important, but our legacy is in the students,” Martinez said. “We want them to graduate with technical excellence, creativity, and the confidence to lead.”

The team has also developed a new way to “print” metals. Instead of relying on heavy blocks of raw material, they created a process that starts with liquid, infused with metal salts. Once printed and treated, these liquids solidify into copper, tungsten, and alloy materials. Copper is essential for everyday power systems, while tungsten withstands extreme heat and radiation, making it vital for aerospace and defense. What this means in practical terms is that parts once dependent on long supply chains could be produced locally, quickly, and on demand. This breakthrough not only advances technology but also enhances the nation’s supply of critical materials.

Recognition has followed, with Maurel and Martinez as the most-cited researchers worldwide in the emerging field of 3D-printed batteries; they have brought visibility to UTEP. Their distinction has led to collaborations with national laboratories and federal agencies and has drawn top students eager to join the Estrella team. “This recognition is not just personal,” Maurel said. “It reflects the strength of our group and the visibility of UTEP as a place where innovation in energy storage is happening.”

The future they envision is both practical and visionary. Safer, longer-lasting batteries could strengthen communities in the wake of disasters. Radiation-resistant and high-temperature materials could support crews and habitats in space. Everyday devices could become lighter and more sustainable. For Maurel and Martinez, the motivation lies in pushing beyond convention while training others to do the same. “We want our research to inspire new ways of thinking about energy and sustainability,” Martinez said. “The future we are building is not just for space exploration. It is for everyday life here on Earth.”

Written by David A. Hernández, Director of Research Development, Research & Innovation.

Point of contact: Ana C. Martínez, Ph.D., Assistant Professor of Research, Department of Metallurgical, Materials & Biomedical Engineering, College of Engineering, University of Texas at El Paso, acmartinezm@utep.edu

Alternate contact: Alexis Maurel, Ph.D., Assistant Professor of Research, Department of Metallurgical, Materials & Biomedical Engineering, College of Engineering, University of Texas at El Paso, amaurel@utep.edu