Vikram Singh, Hidenori Takagi

In the field of Engineering, Mechanical Innovation and Advanced Technology, internal porosity and surface roughness in laser powder bed fusion titanium parts degrade high-cycle fatigue performance. This empirical investigation systematically examines Topology Optimization and Fatigue Life Prediction of Additively Manufactured Ti-6Al-4V Aerospace Brackets through a multi-stage experimental methodology and rigorous quantitative analytical framework. Utilizing finite element topology optimization, X-ray computed tomography porosity scanning, and resonant axial fatigue testing, data were gathered across multiple operational cycles and validated against established international benchmarks. The statistical and computational results reveal that hot isostatic pressing combined with topological mass redistribution achieved a 38% weight reduction while exceeding standard aerospace fatigue life limits. Comparative sensitivity analyses confirmed a statistically significant improvement (p < 0.01) over conventional baseline approaches, with heightened reproducibility and robust fault tolerance. These comprehensive findings provide actionable theoretical insights and practical implementation guidelines for aerospace structural engineers and additive manufacturing production facilities. Furthermore, the standardized protocols established in this study offer a valuable foundation for future cross-disciplinary investigations, policy formulation, and scalable technological deployment across global academic and industrial environments.