In an effort to mitigate supply chain delays and streamline lengthy rapid prototyping processes associated with currently outsourced forging methods, Sikorsky has acquired two additive friction stir deposition machines from MELD Manufacturing Corporation. Leveraging patented MELD technology, a solid-state metal additive process, Sikorsky aims to enhance its manufacturing capabilities by fabricating multi-layer solid components of any metal with refined grain structures and reduced porosity. This project serves as a thorough exploration of process parameter optimization, facilitating the identification and mitigation of process failure modes. Ultimately, this integration project aims to enhance Sikorsky’s cost competitiveness while upholding the stringent material properties and high quality standards required in the aerospace and defense industries.