Sanjay Sampath’s research encompasses the fields of thermal spray processing of materials, synthesis and application of multilayered surfaces and development of direct write technology for thick film sensors and electronics. His specific current research involves an integrated strategy associate with science and technology of thermal spray processing of materials. The program has both fundamental and applied components. The fundamental science relates to the evolution of microstructures associated with far from equilibrium conditions. The applied component is the applicability of the thermal spray fundamentals to industrial processes in coating design, performance and reliability.

In addition, Prof.Sampath has pioneered the development of mesoscale direct writing technologies based on thermal spray for applications in prototyping and manufacturing of wide ranging thick film sensor structures, thick film electronics as well as mesoscale multifunctional systems.