Abstract LPBF has established itself as a transformative technology for producing geometrically complex metallic components, enabling design freedoms unachievable through conventional manufacturing routes. large parts require substantial powder quantities, extended build times, and generate elevated residual stresses that can compromise dimensional accuracy and mechanical integrity. These constraints are particularly acute in fracture mechanics characterisation, where standard specimens most notably the CT specimen specified under ASTM E1820 are inherently massive and solid by design. So, printing CT specimens via LPBF to evaluate fracture toughness imposes a disproportionate material and time cost, rendering systematic and statistically robust testing campaigns both expensive and impractical.