The fatigue life properties of Additive Manufactured (AM) components are limited due to the defects naturally generated from the AM Process. For limited design life problems the finite fatigue life El-Haddad model linked defect size, applied stress, and design life. This paper developed a method to predict the smallest defect of interest for a given load case and the lowest failure generating stress for a given defect size. Experimental testing validated the method steps. The model was adjusted to demonstrate the space utility based on a 12U CubeSat chassis. Applying the design life and expected load, the finite fatigue life El-Haddad model predicted the minimum defect size for two configurations of the 12U CubeSat. The minimum defect size defined the Non-Destructive Evaluation (NDE) criteria for component certification. Combining the worst case potential defect size with the design life, the finite fatigue life El-Haddad model defined a minimum stress to generate failure. Linking the minimum stress value to the CubeSat Finite Element Model (FEM) predicted every location on the structure that could potentially fail due to the formation of AM defects. This second aspect defined the required inspection region to certify the structure for the given load case and design life
