Fluctuations in 3D printing factors, such as the thickness of the printed layer, the laser's intensity, and the scanning speed, have a statistically observable impact on aerospace part mechanical attributes. The mentioned variations influence the samples' microstructural characteristics, the volume of enclosed air pockets, and the residual mechanical force typical of the manufactured components. Such differences cause varying degrees of durability, resistance to material fatigue, and the accuracy in the dimensions of the completed material pieces. A thorough examination enables one to assess the connections between the process variables and how they affect the eventual outcomes in technical terms. This analysis would also reveal the parts that have the most influence on the mechanical attributes. Recognizing this unpredictable nature of these variations facilitates the tailoring of the printing parameters for more consistent quality and dependability of aerospace components. It leads to improved performance, thus also elevating safety.

Overall, parameter uncertainty propagates into mechanical property distributions, which is why probabilistic design and reliability analysis are critical in aerospace AM.