Stainless steel is essential in high-performance industries due to its strength, corrosion resistance, and biocompatibility. However, conventional manufacturing methods limit material efficiency, design complexity, and customization. Additive manufacturing (AM) has emerged as a powerful alternative, enabling the production of stainless-steel components with complex geometries, tailored microstructures, and integrated functionalities. Key AM methodologies, including laser powder bed fusion (L-PBF), binder jetting, and directed energy deposition (DED), are evaluated for their effectiveness in producing stainless-steel components with optimal performance characteristics. This review highlights innovations in stainless-steel AM, focusing on microfabrication, multi-material approaches, and post-processing strategies such as heat treatment, hot isostatic pressing (HIP), and surface finishing. It also examines the impact of process parameters on microstructure, mechanical anisotropy, and defects. Emerging trends include AM-specific alloy design, functionally graded structures, and AI-based control. Applications span biomedical implants, micro-tooling, energy systems, and automotive parts, with emphasis on microfabrication for biomedical micromachines and precision microforming.

A coupled modeling framework is developed to predict coating thickness after air knife wiping in hot-dip galvanizing. A 3D large eddy simulation (LES) using the WALE sub-grid scale (SGS) model is performed to resolve the jet impingement on the moving strip. Time-averaged wall static pressure $p_{\omega }\left(y\right)$ and wall shear stress ${\tau }_{\omega }\left(y\right)$ along the strip direction are extracted and used as driving inputs for a thin film model. Starting from the continuity and momentum equations, a lubrication-type formulation is derived, leading to a local cubic equation for film thickness $h\left(y\right)$ that accounts for both pressure gradient and gravity. A coupling workflow is established to preprocess the LES wall signals and compute the final coating thickness $h_{final}$. Parametric sweeps of inlet total pressure $P_0$ and the knife-to-strip distance $H$ are employed to construct operating window maps. The predicted trends show that increasing $P_0$ or decreasing $H$ intensifies wall loading and reduces $h_{final}$, while the operating window boundary is governed by the balance between the gas-induced shears. Representative results, including peak wall loading and thickness ranges, are reported for industrially relevant operating conditions.