Professor Gao's research interests are in the areas of signal transduction mechanisms for multi-physics sensing, mechatronic systems design, stochastic modeling, multi-resolution data analysis, and artificial intelligence/machine learning for improving the observability and control of manufacturing processes and product quality. His research integrates analytical, numerical, and experimental methods, and has led to the inventions of miniaturized sensors, high-speed measurement instruments, and AI-based data analytic methods to enhance in-situ monitoring and control of manufacturing processes (e.g., plastic injection molding, sheet metal stamping, microrolling, etc.) and prognosis of product quality and system performance (e.g., aircraft engines, building HVAC, batteries, etc.).

His current research addresses AI-enhanced control, intelligence, and autonomy of hybrid autonomous manufacturing processes (e.g., incremental forming and additive manufacturing), which is part of the recently established NSF Engineering Research Center on Hybrid Autonomous Manufacturing: Moving from Evolution to Revolution (NSF ERC HAMMER). He has published three books, over 400 technical papers (including 200 journal articles), 13 awarded patents, and given more than 120 invited talks.