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This work introduces a scalable platform for producing carbonaceous Joule heaters embedded with catalytic nanoparticles from 3D\u2010printed polypropylene precursors, prepared through crosslinking, metal nitration immersion, and pyrolysis steps. Specifically, sulfonate groups on crosslinked PP can bind with metal ions, yielding well\u2010dispersed, nanosized particles within a carbon structure that maintains macroscopic dimensional accuracy throughout the manufacturing. The approach is modular, allowing control over particle size and composition. Structured carbon with in situ loaded nickel nanoparticles demonstrates efficient Joule heating, high catalytic activity, and significantly reduced activation energy for catalytic ammonia decomposition. This work provides an innovative material and manufacturing platform to produce structured, catalytically active Joule heaters for decarbonization of chemical synthesis and energy production.<\/jats:p>","DOI":"10.1002\/advs.202413149","type":"journal-article","created":{"date-parts":[[2025,4,27]],"date-time":"2025-04-27T14:32:11Z","timestamp":1745764331000},"update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":11,"title":["Transformative 3D Printing of Carbon\u2010metal Nanocomposites as Catalytic Joule Heaters for Enhanced Ammonia Decomposition"],"prefix":"10.1002","volume":"12","author":[{"given":"Paul","family":"Smith","sequence":"first","affiliation":[{"name":"School of Polymer Science and Engineering University of Southern Mississippi  Hattiesburg MS 39406 USA"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jiachun","family":"Wu","sequence":"additional","affiliation":[{"name":"Dave C. 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