Abstract: Additive manufacturing (AM) is replacing traditional fabrication methods, offering nearly unlimited possibilities in part design, while allowing precise control across the whole geometry. The automated just-in-time nature of the process, user customization and tailored properties are beneficial for products in aerospace, pharmaceutical and biomedical industries. A variety of AM techniques are employed based on different physical mechanisms with appropriate domains of applicability in terms of materials and scale. In this talk, we will first review AM approaches, systems and applications, with a focus on current capability gaps. We will then introduce Vibration Assisted Printing (VAP), which is a new direct-write technique for rapid processing of extremely viscous precursor mixtures to fabricate propellants, food, ceramics and metal composites at high resolution. A suite of advanced diagnostics based on X-rays and image magnification will be demonstrated that are used to quantify nozzle structural characteristics and material rheology in-situ during the VAP process, as well as the resulting part structure and properties.