Machine Learning (ML) models combined with in-situ sensing offer a powerful solution to address defect detection challenges in Additive Manufacturing (AM), yet this integration raises critical data privacy concerns, such as data leakage and sensor data compromise, potentially exposing sensitive information about part design and material composition. Differential Privacy (DP), which adds mathematically controlled noise to ML models, provides a way to balance data utility with privacy by concealing identifiable traces from sensor data. However, introducing noise into ML models, especially black-box Artificial Intelligence (AI) models, complicates the prediction of how noise impacts model accuracy. This study presents the Differential Privacy-Hyperdimensional Computing (DP-HD) framework, which leverages Explainable AI (XAI) and the vector symbolic paradigm to quantify noise effects on accuracy. By defining a Signal-to-Noise Ratio (SNR) metric, DP-HD assesses the contribution of training data relative to DP noise, allowing selection of an optimal balance between accuracy and privacy. Experimental results using high-speed melt pool data for anomaly detection in AM demonstrate that DP-HD achieves superior operational efficiency, prediction accuracy, and privacy protection. For instance, with a privacy budget set at 1, DP-HD achieves 94.43% accuracy, outperforming state-of-the-art ML models. Furthermore, DP-HD maintains high accuracy under substantial noise additions to enhance privacy, unlike current models that experience significant accuracy declines under stringent privacy constraints.

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