• Achieved a relative density of 99.8% and a surface roughness of 4.2 μm in LPBF Ti-6Al-4V parts through multi-objective optimization.
• Identified laser power and scan speed as the most influential parameters affecting porosity and microhardness.
• The desirability function approach effectively balanced conflicting objectives, providing a single optimal parameter set.
• Microstructural analysis confirmed a refined α' martensitic structure with minimal defects, enhancing mechanical properties.