Metal parts fabricated via additive, hybrid or convergent manufacturing routes often possess deleterious phases, non-homogeneous microstructure and other characteristics which can affect their bulk mechanical properties in-particular tensile, toughness and fatigue performances. As a result, proper materials processing is required to ‘reset’ or modify the microstructural attributes to enhance target mechanical properties. On the other hand, surface properties can be tweaked by development of novel surface protective coatings, case hardening heat treatments on both additively and conventionally manufactured  samples.  We pursue different routes to maintain  isotropy  and  homogeneity  in  large scale additively manufactured components through advanced materials processing routes. In case of surface processing, we focus on functionally graded product development, in-situ and ex-situ impact treatments and hard-facing coating development to enhance reliability of functional components fabricated via both additive and conventional manufacturing routes. One of the major challenges of metal additive manufacturing is increased surface roughness of printed parts. We are working on developing sustainable and effective novel processes to reduce surface roughness of printed parts which can deployed for both external and internal intricate surface regions.