Green manufacturing is the concept of maximizing the productivity along with keeping healthy environment and strong economy by less material waste and preserving the resources. Friction stir additive manufacturing (FSAM) is the subdivision of additive manufacturing and lies in the category of sheet lamination (SL) according to the ASTM F2792. This additive technique is considered a competent candidate for sustainable manufacturing because of producing high-performance structural part with minimal material waste and utilizing less energy without generating fumes as compared to the existing fusion-based additive manufacturing techniques. In FSAM, mechanical properties and microstructure are based on the heat input and material mixing. These two inputs are commonly controlled with rotation speed (rpm), transverse speed (mm/min), plunge depth, tool geometry, and material to be processed. Therefore, in this study, an attempt is done to fabricate aluminum 5083 build of three plates at different rotation speeds (600, 800, 1000 rpm) and transverse speed of 20 mm/min, 30 rev/min. Defects originates, and microhardness of buildup plates were investigated in the build direction. Tunnel, groove, and incomplete stacking defects were noticed in the middle of joining track as compared to the beginning of the joining track. Maximum hardness of 90.9 HV found at 1000 rpm and 20 mm/min and overall, 1.83 hardness decreased in the process which may be improved by selecting optimized process parameters like rotation speed, tilt angle, transverse speed, etc. Further deep research is ongoing to explore the optimized set of process parameter window for preferable microstructure and mechanical properties. © Institute of Technology PETRONAS Sdn Bhd (Universiti Teknologi PETRONAS) 2024.