Manufacturing process design (MPD) represents a design-oriented approach to manufacturing engineering. In this dissertation, Haynes 230 (H230), a solid solution-strengthened Ni-based superalloy, was chosen to meet the material requirements of a microchannel solar receiver (MSR) needed to increase the efficiency and reduce the cost of solar thermal power generation. An MPD was developed to enable the cost-effective production of the MSR revealing the need to increase the height-to-diameter aspect ratio of posts using electrically-assisted (EA) forming in order to reduce the mass and cost of MSR fluidic interconnects. Efforts to validate the MPD through fabrication of sub-scale MSR test articles resulted in several process failures that were used to refine the MPD. Among them, the EA forming and diffusion bonding of MSR micropost arrays was investigated. Electroplastic effects in the EA forming of H230 show a decrease in yield strength accompanied by a reduction in elongation, contrary to precipitation-hardened Nibased alloys. These differences are attributed to reductions in grain size brought on by the rapid precipitation of carbide precipitates, which possess higher electrical conductivity and, thus, produce lower processing temperatures. Results suggest the need to perform solutionizing heat treatments of H230 after EA forming, prior to diffusion bonding, in order to meet the requirements of the MSR.