Additive Manufacturing (AM) is a disruptive technology of this era. Wire cladding based AM to realize complex aerospace parts is the focus in this project. This project aims at simulating this process and capturing the results in the form of a software. The results will also be physically verified. Distortion and residual stresses appear during cladding just as in other manufacturing processes such as casting or welding. Matrix defects and geometric errors arise due to the distortion, residual stresses, spatter etc. Minimizing these problems requires preliminary tests, right part orientation, and right process parameters. Modeling and simulation of the processes of melting and solidification is of great interest and reserves a range of technological modes aiming to optimize production of parts, development of control software, minimize defects and increase production quality of parts. The project will include the multiple simulations of heat and mass transfer processes, residual stresses and thermo shrinkable deformations in production of conventional products using additive formation based on melting of wire materials to create databases of macro- and microstructures of construction metal materials created with different additive formation methods. The work will embrace the implementation of optimal thermal cycles. The project team will develop recommendations on eventual and associated thermal treatment and carry out experimental studies aiming to create statistical models and verify the obtained numerical results. The project result will present the developed prototype of a computer expert system predicting results of parts? additive formation based on melting of wire materials at a set range of control parameters which will be used for production of prototype models of large workpieces in reduction drives for aircraft- and helicopter-manufacturing. The team of PNRPU will concentrate on electron-beam and plasma technologies and their use for production of prototype models of large workpieces in reduction drives for aircraft- and helicopter-manufacturing. The team of Indian Institute of Technology Bombay will aim at developing a Multi-Station Multi-Axis Hybrid Layered Manufacturing (MSMA-HLM) system on which the above finding will be integrated, tested and validated through industrial case studies.