Manufacturing technologies, materials and digital control of after-treatment systems (for exhaust gases from internal combustion engines and thermal powertrains) give an opportunity for developing more adaptable and alternative catalyst solutions and improved environmental performance. Specific development of new materials and structures in the case of after-treatment assemblies aimed to redefine exhaust systems, environmental performances and energy economy, as well as to optimize emission process is significantly important due to the efficiency improvement and pollution reduction. Material composition and operational electronic control lead to an accurate exhaust after-treatment efficiency and emissions thermo-chemical control. Research results are obtained through computer aided modeling and laboratory study. Some innovative technologies are pointed out. After analyzing the actual values and defining model characteristics in order to validate the architecture, than the research result consisting in optimal material definition is discussed. There are spotted the differences between reference operational model of after-treatment and the optimized material model with new properties and improved reliability. The research of the optimal material and manufacturing technology of components from after-treatment system generated results regarding parameters (as temperatures, pressures and gas flows) in operation of the engine. Defining innovative concepts regarding the materials and manufacturing technologies is considered in order to create future development of the after-treatment systems even with more than three way catalysts for multi redox chemical reactions.