This chapter aims to review the current thermal energy storage materials manufacturing routes, both at the laboratory and industrial scales, and to assess their challenges in terms of optimal performance, scalability and future industrialisation. First, an overview is presented on the state-of-the-art development of formulation and production processes for different thermal energy storage materials, including sensible, latent (phase change) and thermochemical materials. A large-scale fabrication method and its quality control protocols are then presented using high-temperature composite phase change materials as an example. Finally, an insight into future trends and opportunities of thermal energy storage manufacturing within the Industry 4.0 framework is discussed.