Laser Powder Bed Fusion (L-PBF) is a leading metal additive manufacturing process capable of producing complex, high-performance components sustainably. AlSi10Mg is one of the most widely used aluminium alloys in L-PBF due to its low density, high mechanical strength, and thermal stability, making it ideal for the aerospace and automotive industries and other demanding applications. However, its large-scale adoption is limited by the challenge of simultaneously optimizing mechanical performance, surface finish, productivity, and cost-effectiveness.

This study examines the influence of layer thickness, laser power, scan speed, and hatch distance on quality, build rate, and cost. Using gas-atomized AlSi10Mg powder, fifty-four cubic specimens were fabricated and analyzed. Scan speed and layer thickness had the greatest impact on densification, with an optimal volumetric energy density of 35–45 J/mm³ achieving >99% relative density with minimal porosity. Higher scan speeds increased pore size, while higher laser power reduced it. The best surface quality was achieved with thinner layers, lower scan speeds, and higher laser powers, whereas higher build rates generally increased roughness.

Mechanical performance correlated with density and pore size, with optimized 60 µm builds matching or exceeding the strength and ductility of 40 µm builds. The highest-performing sample reached UCS = 420 MPa, YS = 340 MPa, and strain at failure = 0.25. Increasing the build rate from 6.7 to 12.5 mm³/s reduced the build time by 40% for single parts and 70% for 16-part batches. A cost model for a turbine wheel case study identified machine time as the dominant cost driver, with up to 70% cost reduction achievable through higher build rates and full platform utilization without compromising density.

These findings show that careful parameter optimization can deliver high quality, mechanical integrity, productivity, and cost efficiency, enabling L-PBF adoption where performance and economics are equally critical.