The advancement of additive manufacturing (AM) has transformed manufacturing into a single-step process. Solid-state AM processes offer significant advantages over fusion-based techniques, including porosity-free deposits, lower residual stresses, wrought-like microstructure, better mechanical properties, improved process control, and higher build rates. This study explores the development of SolidStir® technology, an extrusion-enabled AM process that employs friction stir (FS) technology to enhance structural performance. A conceptual model explaining the process dynamics of SolidStir™ extrusion is developed using a precipitation-strengthened aluminum alloy. Development of SolidStir® extrusion into SolidStir® AM is demonstrated using a thermally stable, precipitation-strengthened alloy. Microstructural and mechanical characterizations highlight the challenges in performance of precipitation-strengthened material resulting from repeated thermal cycles. This challenge is mitigated through the design of thermally stable alloy, exhibiting that process attribute-based material design can achieve exceptional structural performance. A comparison of the performance of thermally stable alloys using SolidStir® AM and additive friction stir deposition further highlights the efficacy of process specific alloy design. Implementation of FS-based AM process could be useful to numerous industries, such as aerospace, automotive, and shipbuilding, due to its capacity to produce high-strength, defect-free products while minimizing environmental impact.