Additive manufacturing (AM) is identified as one of the best techniques in manufacturing components addressing most of the current challenges including material scarcity, design complexity, material compatibility, etc. Stainless steel 316L is one of the promising material candidates in AM due to its extraordinary properties that are useful in a wide variety of industries. Tailoring desired properties locally is heavily investigated in metal AM. This project focuses on investigating the plastic behavior of additively manufactured SS 316L parts printed using laser powder bed fusion (LPBF) specifically to have a strong crystal orientation towards the direction of loading. Parts were printed to have (100), (110), and fiber texture perpendicular to the tensile axis by changing the laser scanning direction. In-situ tensile tests were carried out in a Scanning Electron Microscope (SEM) acquiring electron backscatter diffraction (EBSD) data from the specimen at several strain levels. Schmid Factor (SF) maps, Kernel Average Misorientation (KAM) maps, and Grain orientation spread (GOS) maps were generated using EBSD data. Micromechanisms in plastic deformation of these highly textured AM parts were analyzed based on the crystal orientation and the microstructure. When the influence of crystallographic texture on the micromechanisms of plastic deformation was observed, it was confirmed that a significant difference is present in tensile properties directed with the crystal orientation. During plastic deformation, the crystals were heavily rotated to accommodate slip formations. The slips that are generated at the grains with fiber texture are restricted by the grain boundaries and therefore, showed a higher yield strength. The (100) texture was less prone to plastic deformation. The grains with (110) crystal orientation proved a higher ductility with a perfect slip starting at the grains with higher SFs and showed {111} <110> slip systems.

Wire-arc additive manufacturing (WAAM) is becoming increasingly common for large scale additive manufacturing (AM) applications because of its high deposition rate (2-3 kg/hr.). The rapid temperature changes and subsequent evolution of mechanical properties during AM can lead to large distortion and residual stresses. Finite element modeling of the AM process shows promise to minimize part distortion and residual stresses through improved path planning and process parameter optimization. However, accurate material properties of M250 before and after heat treatment are needed to properly characterize the property evolution from annealed to AM, to aged. Due to limited data on annealed M250, this research presents the mechanical response of solution annealed M250 maraging steel. Testing at temperatures up to 900 degrees Celsius and strain rates from quasi-static to 1 s-1 was performed to provide more representative mechanical properties for AM parts and provide a correlation between AM, aged, and annealed M250 maraging steel.

Selective laser melting of nitrogen gas atomized 17-4PH stainless results in up to 50% lower yield strength and 600% higher elongation compared to traditionally processed, wrought 17-4PH. This drastic difference in mechanical properties is commonly attributed to the presence of high volume fractions of retained austenite within the as-built microstructure. The factors leading to the increased level of retained austenite have not been clarified in the literature. Furthermore, the amount of retained austenite reported within published literature vary widely, even with the use of identical process parameters. Manufacturers of selective laser melting systems state that solution annealing and precipitation hardening will achieve traditional mechanical properties, thereby removing all retained austenite. Once again, it is not clear, how the recommended solution and precipitation treatments lead to the desired changes in microstructure. The research within this thesis establishes that there is up to 0.12wt% higher nitrogen content within additively manufactured 17-4PH, compared to traditionally manufactured 17-4PH, as a result of the powder atomization process. The increased nitrogen is able to stabilize the austenitic phase by reducing the Ms temperature below ambient temperatures. Fertiscope bulk phase analysis demonstrates that the processing atmosphere during selective laser melting cannot alter the fraction of retained austenite in the as-built material. The depression of the Ms temperature in the printed parts is confirmed by dilatometry. Due to the TRIP phenomenon, during sample preparation, it was found that the austenite would transform to 80% martensite at the surface. This transformation will greatly impact the phases detected when x-ray diffraction is used for analysis, leading to a wide variety of reported retained austenite values within literature. A mechanism based on the precipitation of nitrides during solution-treatment has been proposed to explain how heat-treatment of the printed parts can lead to a martensitic microstructure with comparable mechanical properties to those of wrought alloys. / Thesis / Master of Applied Science (MASc) / 17-4PH stainless steel is a martensitic alloy, that can be precipitation hardened when used in traditional manufacturing processes. Within a selective laser melting process, it will exhibit up to 50% lower yield strength and 600% higher elongation. This behaviour is caused by retained austenite, which is stabilized by the introduction of nitrogen during the powder atomization process. As a result, the alloy exhibits transformation induced plasticity. Existing literature states the alloy’s microstructure can be controlled by altering the selective laser melting process atmosphere or using heat treatment to achieve traditional mechanical properties. However, the production and preparation of samples generates a surface transformation which was misinterpreted as a complete bulk transformation. Therefore, the change in microstructure from altering the process atmosphere is only detectable through surface analytical techniques. It is proposed that the rapid cooling rates of SLM form a non-equilibrium state, keeping nitrogen in solution. Subsequent heat treatment allows the formation of nitrides resulting in the Ms being brought above room temperature.

The information contained in this thesis explores ways to develop a habitat for human settlement on Mars. Currently, most designs for living on Mars focus primarily on survival and emphasize the technological aspects necessary for sustaining life. However, there is a lack of holistic consideration for what life on Mars would entail beyond mere survival. These existing designs are understandably geared towards astronauts who will spend only a few months on Mars. In contrast, this project is dedicated to envisioning the future of Mars settlement, aiming to support astronauts who intend to permanently live and establish communities on Mars, ultimately transforming them into Martians. The project adopts a human-centric approach by integrating biophilic design principles to enhance the well-being of future Martian inhabitants. It seeks to address potential psychological challenges that settlers on Mars may encounter, offering innovative solutions rooted in biophilia. This approach aims to create environments that foster connection with nature, promote mental health, and support overall quality of life for individuals living on Mars. Humans have evolved over millions of years to thrive on Earth, and many of our primal instincts are deeply rooted in our hunter-gatherer ancestry. Transitioning humans to live on another planet would uproot them from their natural environment, potentially depriving them of these primal instincts and causing psychological challenges. (Szocik, n.d.) This project aims to address these issues through architectural solutions. By designing habitats that consider and accommodate our innate instincts and connections to nature, we can mitigate the psychological impacts of living on a different planet. The goal is to create environments on Mars that resonate with our evolutionary heritage, fostering psychological well-being and adaptation in extra-terrestrial settlements. / Master of Architecture / This thesis looks at how to create a habitat for humans to live on Mars. Right now, most designs focus mainly on survival and the technology needed to sustain life. Most don't really consider what everyday life would be like beyond just staying alive. Most current designs are for astronauts who will only be on Mars for a few months. This project, however, imagines a future where people live on Mars permanently and form communities, essentially becoming Martians. The project uses a design method that focuses on human needs at a subconscious and psychological level. It incorporates biophilic design principles, which emphasize our connection to nature, to improve the well-being of future Martian inhabitants. This approach aims to address psychological challenges that settlers on Mars might face, offering innovative solutions based on biophilia. The goal is to create environments that foster a connection with nature, promote mental health, and support a good quality of life. Humans have evolved over millions of years to live on Earth, and many of our basic instincts are tied to our hunter-gatherer ancestors. Moving to another planet could take us away from our natural environment and cause psychological challenges. This project aims to tackle these issues through thoughtful architectural design. By creating habitats that consider our natural instincts and connections to nature, we can reduce the psychological impacts of living on Mars. The goal is to design environments that align with our evolutionary background, helping people adapt and thrive in extra-terrestrial settlements.

Additive friction stir deposition (AFSD) is a solid-state additive manufacturing (AM) technique that breaks down large constituent particles into more refined and uniformly disturbed microstructure. AFSD was used to print Al-Ce alloys. Current commercial Al-alloys upon elevated temperatures go through dissolution and coarsening of strengthening precipitates causing mechanical degradation of these alloys. Al-Ce alloys do not have this issue as cerium's low solubility restricts dissolution into the aluminum matrix at elevated temperatures, thus giving great thermal stability to the microstructure. Al-Ce alloys lack solid solubility that affects the solid solution strengthening and precipitation strengthening. Al-Ce alloys have limitation at room temperature as they can only reach a maximum of ~65 MPa yield strength. Elements like magnesium have been added to alloy to enable solid solution strengthening, and scandium to enable precipitation strengthening to improve strength before going through the AFSD process. By adding new elements to the Al-Ce alloys, an increase in the yield strength from ~60 MPa to ~200 MPa was achieved before AFSD. The casted alloys form coarse particles that reach 300 µm in size; resulting in stress concentration that causes material fracture before necking, giving >10% ductility. AFSD breaks down these coarse particles to increase strength and ductility increases. The particles were broken down to >20 µm which increased the ductility to 10%. The results of this research shows that Al-Ce alloys are able to reach commercial aluminum alloy mechanical standards of 400 MPa ultimate tensile strength and 10% ductility at room temperature for aerospace applications.

Nanomaterials are becoming increasingly prevalent in final use products as we continue to improve our understanding of their structure and properties and optimize their processing. The useful applications for these materials extend from new drug delivery systems to improved materials for various transport industries and many more. Nanoscale materials which are commonly used include but are not limited to carbon nanotubes, graphene, silica, nanoclays, and cellulose nanocrystals. The literature presented herein aims to investigate structure-process-property relationships of cellulose nanocrystal (CNC) polymer composites. These CNC nanocomposites are unique in that they provide a dynamic mechanical response when exposed to H2O. Currently, these nanocomposite systems are most commonly solvent cast into their final geometry. In order to enable the use of these materials in more commercial processing methods such as extrusion, we must understand their inherent structure-process-property relationships. To do this, we first characterize the influence of temperature and shear orientation on the unique mechanical adaptive response. Next, the melt processability of the nanocomposite was characterized using material extrusion (MatEx) additive manufacturing (AM). Additionally, the diffusion behavior of water within the film, which controls the dynamic mechanical response, was probed to better predict the concentration dependent behavior. Finally, a literature review is presented which outlines the state of the art for melt extrusion AM of fiber filled polymer composite materials and provides insight into how we can further improve mechanical properties through further addition of composite filler materials. The initial focus of the dissertation is on the influence of melt processing CNC thermoplastic urethane (TPU) composites and the resulting impact on the mechanical adaptive response. Dynamic mechanical analysis (DMA) fitted with a submersion clamp was used to measure the mechanical softening of the composite while submerged in water. Small angle x-ray scattering (SAXS) and polarized raman spectroscopy were used to qualify the orientation of the various CNC/TPU composite samples. The results of the orientation measurements show that solvent casting the films orient CNCs into a mostly random state and melt extrusion induces some degree of uniaxial orientation. The DMA results indicate that at the processing conditions tested, the uniaxial orientation and thermal exposure from the melt processing do not significantly impact the mechanical responsiveness of the material. The next objective of this work was to expand upon the aforementioned learnings and determine the CNC composite material processability using MatEx. The ability to process mechanically dynamic CNC/TPU composites with a selective deposition process capable of generating complex geometries may enable new functionality and design freedom. To realize this potential, a two factor (extrusion temperature and extrusion speed) three level (240, 250 and 260 ℃/ 600, 1100 and 1600 mm/min) design of experiments (DOE) was utilized. The resulting printed parts were characterized by DMA to determine their respective mechanical adaptivity. Processing conditions did prove to have a significant impact on the mechanical adaptivity of the printed part. A correlation between applied energy and mechanical adaptivity demonstrates how increasing residence time and temperature can reduce mechanical performance. The shape fixity of the printed parts was calculated to be 80.4% and shape recovery was 44.2%. A 3D prototype part was also produced to demonstrate the unique properties of this material. Although the understanding of the melt processing behavior of these CNC composites had been improved, a stronger understanding of the moisture diffusion behavior within the composite is required to fully realize and control their potential. Therefore, a study was undertaken to capture the diffusion behavior and correlate it to the mechanical responsive mechanism. To do this, a thermogravimetric sorption analysis (TGA-SA) instrument was used to monitor the mass uptake as a function of time exposed to a humid environment. These data were then compared to DMA data collected for the same samples exposed to a similar degree of humidity. All studies were conducted as a function of concentration in order to better elucidate the influence that percolating network structures may have on the resultant properties. Interestingly, the results show how increasing addition of CNCs results in a decrease in the rate of diffusivity, which is counter to what has been commonly hypothesized. It is hypothesized that increasing CNC content restricts the mobility of surrounding amorphous matrix material, thus increasing the resistance for diffusion of a water molecule. However, the rate of mechanical adaptation was found to increase with increasing CNC content, which is believed to be a result of the increased connectivity, enabling further transport of water molecules. / Doctor of Philosophy / Nanomaterials are becoming increasingly prevalent in final use products as we continue to improve our understanding of their structure and properties and optimize their processing. The useful applications for these materials extend from new drug delivery systems to improved materials for various transport industries and many more. The literature presented herein aims to investigate structure-process-property relationships of cellulose nanocrystal (CNC) polymer composites. These CNC nanocomposites are unique in that they provide a unique mechanical response when exposed to water. In order to enable the use of these materials in more commercial processing methods, we must understand their inherent structure-process-property relationships. The following documents multiple aspects of these unique composite materials which enables their commercial viability and scientific versatility.

Vat photopolymerization's (VP) use in large-scale industrial manufacturing is limited due to poor scalability, and limited catalogue of engineering polymers. The challenges in scalability stem from an inherent process paradox: the feature resolution, part size, and manufacturing throughput cannot be maximized simultaneously in standard VP platforms. In addition, VP's inability to process viscous and high-molecular weight engineering polymers limits the VP materials catalogue. To address these limitations, the research presented in this work was conducted in two stages: (1) Development and modeling of new VP platforms to address the scalability and viscosity challenges, and (2) Investigating the influence of using the new processes on the cured polymer network structure and mechanical properties. First, a scanning mask projection vat photopolymerization (S-MPVP) system was developed to address the scalability limitations in VP systems. The process paradox was resolved by scanning the mask projection device across the resin surface while simultaneously projecting the layer as a movie. Using actual projected pixel irradiance distribution, a process model was developed to capture the interaction between projected pixels and the resin, and predict the resulting cure profile with an error of 2.9%. The S-MPVP model was then extended for processing heterogeneous UV scattering resins (i.e. UV curable polymer colloids). Using computer vision, the scattering of incident UV radiation on the resin surface was successfully captured and used to predict scattering-compensated printing parameters (bitmap pattern, exposure time , scanning speed). The developed reverse-curing model was used to successfully fabricate complex features using photocurable SBR latex with XY errors < 1.3%. To address the low manufacturing throughput of VP systems, a recoat-less, volumetric curing VP system that fabricates parts by continuously irradiating the resin surface with a movie composed of different gray-scaled bitmap images ( Free-surface movie mask projection (FreeMMaP)) was developed. The effect of cumulative exposure on the cure profile (X,Y,Z dimensions) was investigated and used to develop an iterative gray-scaling algorithm that generated a combination of gray-scaled bitmap images and exposure times that result in accurate volumetric curing (errors in XY plane and Z axis < 5% and 3% respectively). Results of this work demonstrate that the elimination of the recoating process increased manufacturing speed by 8.05 times and enabled high-resolution fabrication with highly viscous resins or soft gels. Then, highly viscous resins were made processible in VP systems by using elevated processing temperatures to lower resin viscosity. New characterization techniques were developed to determine the threshold printing temperature and time that prevented the onset of thermally-induced polymerization. The effect of printing temperature on curing, cured polymer structure, cured polymer mechanical properties, and printable aspect ratio was also investigated using diacrylate and dimethacrylate resins. Results of this investigation revealed increasing printing temperature resulted in improvements in crosslink density, tensile strength, and printability. However, presence of hydroxl groups on the resin backbone caused deterioration of crosslink density, mechanical properties, and curing properties at elevated printing temperatures. Finally, the lack of a systematic, constraint based approach to resin design was bridged by using the results of earlier process-structure-property explorations to create an intuitive framework for resin screening and design. Key screening parameters (such as UV absorptivity, plateau storage modulus) and design parameters (such as photoinitiator concentration, polymer concentration, UV blocker concentration) were identified and the methods to optimize them to meet the desired printability metrics were demonstrated using case studies. Most work in vat photopolymerization either deal with materials development or process development and modeling. This dissertation is placed at the intersection of process development and materials development, thus giving it an unique perspective for exploring the inter-dependency of machine and material. The process models, machines and techniques used in this work to make a material printable will serve as a guide for chemists and engineers working on the next generation of vat photopolymerization machines and materials. / Doctor of Philosophy / Vat Photopolymerization (VP) is a polymer-based additive manufacturing platform that uses UV light to cure a photo-sensitive polymer into the desired shape. While parts fabricated via VP exhibit excellent surface finish and high-feature resolution, their use for commercial manufacturing is limited because of its poor scalability for large-scale manufacturing and limited selection of engineering materials. This work focuses on the development of new VP platforms, process models and the investigation of the process-structure-property relationships to mitigate these limitations and enable fabrication of performance polymers. The first section of the dissertation presents the development of two new VP platforms to address the limitations in scalability. The Scanning Mask Projection Vat Photopolymerization (S-MPVP)) was developed to fabricate large area parts with high-resolution features and the Free-surface movie mask projection (FreeMMaP) VP platform was developed to enable high-speed, recoat-less, volumetric fabrication of 3D objects. Computer-vision based models were developed to investigate the influence of these new processes on the resultant cure shape and dimensional accuracy. Process models that can: (1) predict the cure profile for given input printing parameters (error < 3%), (2) predict the printing parameters (exposure time, bitmap gray-scaling) required for accurate part fabrication in homogeneous and UV scattering resins, and (3) generate gray-scaled bitmap images that can induce volumetric curing inside the resin (dimensional accuracy of 97% Z axis, 95% XY axis), were designed and demonstrated successfully. In the second portion of this work, the use of high-temperature VP to enable processing of high-viscosity resins and expansion of materials catalogue is presented. New methods to characterize the resin's thermal stability are developed. Techniques to determine the printing temperature and time that will prevent the occurrence of thermally-induced polymerization are demonstrated. Parts were fabricated at different printing temperatures and the influence of printing temperature on the resultant mechanical properties and polymer network structure was studied. Results of this work indicate that elevated printing temperature can be used to alter the final mechanical properties of the printed part and improve the printability of the high-resolution, slender features. Finally, the results of the process-structure-property investigations conducted in this work were used to guide the development of a resin design framework that highlights the parameters, metrics, and methods required to (1) identify printable resin formulations, and (2) tune printable formulations for optimal photocuring. Elements of this framework were then combined into an intuitive flowchart to serve as a design tool for chemists and engineers.

Metal additive manufacturing stands poised to disrupt multiple industries with high material use efficiency and complex part production capabilities, however many technologies deposit material with sub-optimal properties, limiting their use. This decrease in performance largely stems from porosity laden parts, and asymmetric solidification-based microstructures. Solid-state additive manufacturing techniques bypass these flaws, using deformation and diffusion phenomena to bond material together layer by layer. Among these techniques, Additive Friction Stir Deposition (AFSD), stands out as unique for its freeform nature, and thermomechanical conditions during material processing. Leveraging its solid-state behavior, optimized microstructures produced by AFSD can reach performance levels near, at, or even above traditionally prepared metals. A strong understanding of the material conditions during AFSD and the phenomena responsible for microstructure evolution. Here we discuss two works aimed at improving the state of knowledge surrounding AFSD, promoting future microstructure optimization. First, a parametric study is performed, finding a wide array of producible microstructures across two material systems. In the second work, a stop-action type experiment is employed to observe the dynamic microstructure evolution across the AFSD material flow pathway, finding specific thermomechanical regimes that occur within. Finally, multiple conventional alloy systems are discussed as their microstructure evolution pertains to AFSD, as well as some more unique systems previously limited to small lab scale techniques, but now producible in bulk due to the additive nature of AFSD. / Doctor of Philosophy / The microstructure of a material describes the atomic behavior at multiple length scales. In metals this microstructure generally revolves around the behavior of millions of individual crystals of metal combined to form the bulk material. The state and behavior of these crystals and the atoms that make them up influence the strength and usability of the material and can be observed using various high fidelity characterization techniques. In metal additive manufacturing (i.e. 3D printing) the microstructure experiences rapid and severe changes which can alter the final properties of the material, typical to a detrimental effect. Given the other benefits of additive manufacturing such as reduced costs and complex part creation, there is desire to predict and control the microstructure evolution to maximize the usability of printed material. Here, the microstructure evolution in a solid-state metal additive manufacturing, Additive Friction Stir Deposition (AFSD), is investigated for different metal material systems. The solid-state nature of AFSD means no melting of the metal occurs during processing, with deformation forcing material together layer by layer. The conditions experienced by the material during printing are in a thermomechanical regime, with both heating and deformation applied, akin to common blacksmithing. In this work specific microstructure evolution phenomena are discussed for multiple materials, highlighting how AFSD processing can be adjusted to change the resulting microstructure and properties. Additionally, specific AFSD process interactions are studied and described to provide better insight into cumulative microstructure evolution throughout the process. This work provides the groundwork for investigating microstructure evolution in AFSD, as well as evidence and results for a number of popular metal systems.

The research presented in this dissertation supports the overall goal of producing sensor functionalized neural microphysiological systems to enable deeper fundamental understandings of disease pathology and to provide drug screening and discovery platforms for improved clinical translation. Towards this goal, work addressing three broad objectives has been completed. The first objective was expanding the manufacturing process capabilities for hydrogels and tissues through augmentation of the 3D printing systems and developing novel modeling capabilities. The second objective was to expand the palette of available materials which exhibit the rheological properties required for 3D printing and the mechanical and biological properties required for neural tissue culture. The third objective was to develop sensing capabilities for both monitoring and control of the manufacturing process and to provide non-destructive assessment of microphysiological systems in real-time to quantify the dynamics of disease progression or response to treatment. The first objective of process improvement was addressed both through modification of the 3D printing system itself and through modeling of process physics. A new manifold was implemented which enabled on-the-fly mixing of bioprinting inks (bioinks) to produce smooth concentration gradients or discrete changes in concentration. Modeling capabilities to understand the transport occurring during both the processing and post-processing windows were developed to provide insight into the relationship between the programmed concentration distribution and its temporal evolution and stability. Vacuum-based pick-and-place capabilities for integration of prefabricated components for sensing and stimulation into the printed hydrogel constructs were developed. Models of the stress profiles, which relate to cell viability, within the printing nozzle during extrusion were produced using parameters extracted from rheological characterization of bioinks. The second objective was addressed through the development hydrogel bioinks which exhibited yield stresses without the use of rheological modifiers (fillers) to enable 3D printing of free-standing neural tissue constructs. A hybrid bioink was developed using the combination of a synthetic polaxamer with biomacromolecules present in native neural tissue. Functionalization of the biomacromolecules with catechol or methacrylate groups enabled two crosslinking mechanisms: chelation and UV exposure. Crosslinked gels exhibited moduli in the range of native neural tissue and enabled high viability culture of multiple neural cell types. The third objective was addressed through the characterization and implementation of physical and electronic sensors. The resonance of millimeter-scale dynamic-mode piezoelectric cantilevers submerged in polymer solutions was found to persist into the gel phase enabling viscoelastic sensing in hydrogels and monitoring of sol-gel transitions. Resonant frequency and quality factor of the cantilevers were related with the viscoelastic properties of hydrogels through both a first principles approach and empirical correlation. Electrode functionalized hollow fibers were implemented as impedimetric sensors to monitor bioink quality during 3D printing. Impedance spectra were collected during extrusion of cell-laden bioinks and the magnitude and phased angle of the impedance response correlated with quality measures such as cell viability, cell type, and stemness which were validated with traditional off-line assays. / Doctor of Philosophy / The research presented in this dissertation supports the overall goal of producing sensor functionalized neural microphysiological systems to enable deeper fundamental understandings of disease pathology and to provide drug screening and discovery platforms for improved clinical translation. Microphysiological systems are miniaturized tissue constructs which strive to mimic the complex conditions present in-vivo within an in-vitro platform. By producing these microphysiological systems with sensing functionality, new insight into the mechanistic progression of diseases and the response to new treatment options can be realized. Towards this goal, work addressing three broad objectives has been completed. The first objective was expanding the manufacturing process capabilities for hydrogels and tissues through augmentation of the 3D printing systems and developing novel modeling capabilities. The second objective was to expand the palette of available materials which exhibit both the properties required for 3D printing and the mechanical and biological properties required for neural tissue culture. The third objective was to develop sensing capabilities for both monitoring and control of the manufacturing process and to provide non-destructive assessment of microphysiological systems in real-time to quantify the dynamics of disease progression or response to treatment. Through these efforts higher quality microphysiological systems may be produced benefitting future researchers, medical professionals, and patients.

Additive manufacturing (AM) is a growing section of the advanced manufacturing field and is being used to fabricate an increasing number of critical components, from aerospace components to medical implants. At the same time, cyber-physical attacks targeting manufacturing systems have continued to rise. For this reason, there is a need to research new techniques and methods to ensure the integrity of parts fabricated on AM systems. This work seeks to address this need by first performing a detailed analysis of vulnerabilities in the AM process chain and how these attack vectors could be used to execute malicious part sabotage attacks. This work demonstrated the ability of an internal void attack on the .STL file to reduce the yield load of a tensile specimen by 14% while escaping detection by operators. To mitigate these vulnerabilities, a new impedance-based approach for in situ monitoring of AM systems was created. Two techniques for implementing this approach were investigated, direct embedding of sensors in AM parts, and the use of an instrumented fixture as a build plate. The ability to detect changes in material as small as 1.38% of the printed volume (53.8 mm3) on a material jetting system was demonstrated. For metal laser powder bed fusion systems, a new method was created for representing side-channel meltpool emissions. This method reduces the quantity of data while remaining sensitive enough to detect changes to the toolpath and process parameters caused by malicious attacks. To enable the SCMS to validate part quality during fabrication required a way to receive baseline part quality information across an air-gap. To accomplish this a new process noise tolerant method of cyber-physical hashing for continuous data sets was presented. This method was coupled with new techniques for the storage, transmission, and reconstructing of the baseline quality data was implemented using stacks of "ghost" QR codes stored in the toolpath to transmit information through the laser position. A technique for storing and transmitting quality information in the toolpath files of parts using acoustic emissions was investigated. The ATTACH (additive toolpath transmission of acoustic cyber-physical hash) method used speed modulation of infill roads in a material extrusion system to generate acoustic tones containing quality information about the part. These modulations were able to be inserted without affecting the build time or requiring additional material and did not affect the quality of the part that contained them. Finally, a framework for the design and implementation of a SCMS for protecting AM systems against malicious cyber-physical part sabotage attacks was created. The IDEAS (Identify, Define, Establish, Aggregate, Secure) framework provides a detailed reference for engineers to use to secure AM systems by leveraging the previous work in vulnerability assessment, creation of new side-channel monitoring techniques, concisely representing quality data, and securely transmitting information to air-gapped systems through physical emissions. / Doctor of Philosophy / Additive manufacturing (AM), more widely known as 3D printing, is a growing field of manufacturing where parts are fabricated by building layers of material on top of each other. This layer-based approach allows the production of parts with complex shapes that cannot be made using more traditional approaches such as machining. This capability allows for great freedom in designing parts, but also means that defects can be created inside of parts during fabrication. This work investigates ways that an adversary might seek to sabotage AM parts through a cyber-physical attack. To prevent attacks seeking to sabotage AM parts several new approaches for security are presented. The first approach uses tiny vibrations to detect changes to part shape or material by attaching a small sensor either directly to the parts or to the surface that they are built on. Because an attack that sabotages an AM system (3D printer) could also affect the systems used to detect part defects these systems should be digitally separated from each other. By using a series of QR codes fabricated by the AM system along with the parts, information can be sent from the AM system to the monitoring system through its sensors. This prevents a cyber-attack from jumping from the AM system to the monitoring system. By temporarily turning off the laser power and tracking the movements of the guiding mirrors the QR code information can be sent to the monitoring system without having to actually print the QR code. The information stored in the QR code is compared to the emission generated when fabricating the parts and is used to detect if an attack has occurred since that would change the emissions from the part, but not from the QR code. Another approach for sending information from the AM system using physical emissions is by using sounds generated during part fabrication. Using a desktop scale 3D printer, the speed of certain movements was increased or decreased. The change in speed causes the sound emitted from the printer to change, while not affecting the actual quality of the print. By using a series of tones, similar to Morse code, information can be sent from the printer. Research was performed on the best settings to use to transmit the information as well as how to automatically receive and decode the information using a microphone. The final step in this work is a framework that serves as a guide for designing and implementing monitoring systems that can detect sabotage attacks on AM parts. The framework covers how to evaluate a system for potential vulnerabilities and how to use this information to choose sensors and data processing techniques to reduce the risk of cyber-physical attacks.