<p>This investigation examines additive manufacturing (AM) technology, focusing on laser powder bed fusion (LPBF), to evaluate its potential for producing functional internal combustion (IC) engine parts for automobiles, aeroplanes, and fighter jets. The 3D printing of an exhaust valve of a commercially available passenger vehicle (PV) diesel engine is the subject of this study, which focuses on its porosity and surface roughness (SR). Generally, the engine valves are manufactured by the casting route, leading to fatigue issues due to porosity, SR, microcracks, stress–strain residual status, and microstructure concerns. This research work focuses on the production of PV exhaust valves by an alternate route. The traditional and 3D metal-printed exhaust valve are compared on the basis of porosity and surface roughness. It has been observed that the SR is low at all the locations for the 3D-printed exhaust valve over the traditional exhaust valve. The SEM images shown for the traditional exhaust valve revealed that a narrow but relatively deep wear track was formed on the surface at the valve head, while the image at the same location of 3D printed exhaust valve shows that there are very small or no wear tracks. The exhaust valve model was prepared from Inconel 718 material. The cracks, geometric abnormalities, and porosity were among the problems that were quantified using microcomputed tomography (μCT) scans. Machining and post-processing (heat treatment) followed after confirming component viability. Micro-CT scan confirmed features within original equipment manufacturer's (OEM) limit. It has been found from the CT scans of the 3D metal-printed exhaust valve that it has substantially lower porosity percentages, surely making them stronger than the traditional way exhaust valve.</p>