Scalmalloy, an aluminum–magnesium–scandium alloy, is renowned for its exceptional strength-to-weight ratio and high ductility, making it a prime candidate for aerospace and space applications. This study focuses on optimizing the Laser Powder Bed Fusion (L-PBF) process parameters to enhance the print quality and mechanical properties of Scalmalloy components tailored for space electronic packaging applications where precise complex wall geometries and shape stability are crucial.

Employing Design of Experiments methodologies, we systematically varied key process parameters, including layer height, laser power, scanning speed, and hatch spacing. Standardized cubic specimens were fabricated across a range of energy densities to establish correlations between process parameters, porosity levels, and mechanical strength. Comprehensive analyses were conducted to evaluate the performance of these specimens. Our findings indicate that an optimal energy density window of 90 to 125 J∙mm⁻³ minimizes porosity while maximizing mechanical performance.

Utilizing these optimized parameters, we designed and developed prototype components intended for space applications, emphasizing lightweight structures, thermal stability, and structural integrity. The results demonstrate that precise control of L-PBF parameters facilitates the production of Scalmalloy parts with superior mechanical properties and minimal defects, aligning with the stringent requirements of space applications. This research underscores the significance of parameter optimization in additive manufacturing to achieve resource-efficient production of high-performance metallic components.