Start by tying inspection to functional risks (flow area, wall thickness, minimum radii, blockage, and defect types). Specify: (a) which internal dimensions/features must be measured versus qualitatively assessed; (b) required CT voxel size/resolution and scan orientation; (c) defect acceptance limits (e.g., maximum pore size, lack-of-fusion indications, un-melted powder, or inclusions) and where they are allowed/not allowed; (d) reporting requirements (dimensional report, defect map, and raw data retention if required); and (e) correlation/validation method (CT-to-CMM where possible, destructive sectioning on coupons or first articles, and gage R&R/MSA for the CT workflow). Align these criteria before first article to avoid late disputes over what CT “proves.”

Treat changes as major when they can alter material properties, defect population, or dimensional stability. Common triggers include: machine model/serial change; parameter set changes (laser power/speed/hatch, scan strategy, layer thickness); build orientation changes for critical features; powder supplier change, powder chemistry limits, or significant powder reuse policy changes; HIP cycle changes (temperature/pressure/hold time), HIP vendor change, or furnace change; heat treat recipe or furnace change; container design or powder loading method changes for PM-HIP; and changes to critical post-processing (support removal method, surface finishing, or machining datum scheme). Define these triggers in the PO/quality clauses and require documented impact assessment and approval path (notification, MRB disposition, or requalification plan) before implementation.

Request objective controls and capability evidence: (a) a proposed manufacturing and inspection plan identifying which features are held net-shape vs machined and where datums are established; (b) historical process capability where available (Cp/Cpk or equivalent) for analogous features and materials; (c) documented powder/feedstock controls and lot traceability procedures; (d) thermal cycle control records (HIP/heat treat) and furnace calibration status; (e) NDE/CT capability details including resolution limits and MSA; (f) a plan for witness coupons/test bars (location, orientation, quantity, and test matrix) that matches the part’s critical stress directions; and (g) a change-control and nonconformance workflow (MRB, corrective action, and record retention). These items make supplier comparisons defensible for engineering and procurement reviews.