Maciej Mazur

Maciej Mazur is a Senior Lecturer at RMIT University’s Centre for Additive Manufacturing whose research advances design and optimisation for additive manufacturing. His research focuses on the additive manufacture of light-weight cellular materials, industrial tooling, fluid flow devices, and aerospace propulsion components, for applications in the chemical science, aerospace and manufacturing industries.

His research contributions span the design-to-performance continuum, from computational enablement of complex, support-free geometries to experimentally validated components with tailored mechanical and thermal behaviour. A defining focus of Maciej's research focuses on metal cellular materials fabricated by laser powder bed fusion. He and his colleagues have identified geometry–property relationships and deformation and failure mechanisms across a range of lattice structure designs. These contributions laid the foundation for further collaborative contributions in the functional surface engineering of additively manufactured cellular materials, for applications in catalysis such as endothermic catalytic cracking of jet fuels for thermal management in hypersonic aircraft. 

Maciej’s work has a strong focus on design for additive manufacturing (DfAM) to leverage its unique capabilities, including the development of patented uniform fractal flow distributors and mixer designs. He has also advanced the design for additive manufacture of industrial tooling, developing design methods for conformally cooled plastic injection moulds and aluminium extrusion dies—work that couples numerical modelling with experimental validation to improve tool performance and reliability.

Beyond structural design, Maciej contributes to process development and manufacturability across metals and polymers. His studies link alloy composition and process parameters to defect formation and mechanical properties in Inconel 625, address the machining of additively manufactured Ti‑6Al‑4V, and establish review-backed strategies for void reduction in material extrusion FDM processes, including new interlaced toolpaths to suppress porosity. Maciej is also an active educator in advanced manufacturing and design topics. He is a co-author of chapters in several books focused on AM of cellular materials, AM for Chemical Sciences and Engineering, as well as AM for Critical Minerals. Earlier in his career, he contributed to computer-aided tolerancing and stochastic variation in assemblies, automotive seat design and optimization, wheelchair biomechanics, and shape-memory actuators—foundations that inform his current emphasis on robust, end-to-end design and validation.

His publications have attracted more than 3,600 citations, with an h‑index of 21, reflecting high‑impact contributions that have helped move additive manufacturing from geometric possibility to engineered performance across structural, thermal, and chemical sciences applications.