Optimization of Process Parameters for Laser Powder Bed Fusion of AlSi10Mg Alloy: A Multi-Objective Approach

• Achieved near-full density (99.8%) and improved mechanical properties (UTS 420 MPa) in AlSi10Mg LPBF parts through multi-objective optimization. • Identified optimal process parameters (laser power 350 W, scan speed 1200 mm/s, hatch spacing 0.12 mm) using RSM and desirability function. • Demonstrated that surface roughness and density can be simultaneously optimized, reducing the need for post-processing. • Provided a validated predictive model that can be extended to other alloys and additive manufacturing processes.