Selective laser melting (SLM) is a process that produces near full density metal parts with mechanical properties comparable to bulk materials. Unlike selective laser sintering (SLS), SLM fully melts the powder particles, leading to higher density and avoiding post-processing. However, this process is more challenging to control due to high energy input and the resulting thermal stresses, balling, and deformation. This study investigates SLM applied to a mixture of Fe, Ni, Cu, and Fe₃P powders. The powder mixture was designed for high density and mechanical properties, with grain sizes below 60 μm for Fe, Cu, and Fe₃P, and below 5 μm for Ni. The powder has an apparent density of 3.17 g/cm³ and a true density of 8.01 g/cm³. The experiments were conducted using a laser with a wavelength of 1.064 μm and a maximum power of 300 W. The build platform was moved with a resolution of 10 μm, and the powder layers were deposited using a roller. The building stage was placed in a vacuum chamber to prevent oxidation. The study examined thermal deformations, including the temperature gradient mechanism (TGM), which causes bending due to temperature differences. Different scanning strategies were tested to minimize deformation, with successive scanning being more effective than the least heat influence (LHI) method. The study also investigated the balling effect, which occurs when molten material does not wet the substrate, leading to rough surfaces and lower density. The vaporization effect was also studied, where high laser power and scan speed reduce balling and improve part density and strength. The results showed that pulsed laser operation with high peak power reduces balling and improves mechanical properties. The maximum bending strength achieved was 630 MPa at a density of 91%. The study concluded that optimizing process parameters is crucial for achieving high-quality SLM parts.Selective laser melting (SLM) is a process that produces near full density metal parts with mechanical properties comparable to bulk materials. Unlike selective laser sintering (SLS), SLM fully melts the powder particles, leading to higher density and avoiding post-processing. However, this process is more challenging to control due to high energy input and the resulting thermal stresses, balling, and deformation. This study investigates SLM applied to a mixture of Fe, Ni, Cu, and Fe₃P powders. The powder mixture was designed for high density and mechanical properties, with grain sizes below 60 μm for Fe, Cu, and Fe₃P, and below 5 μm for Ni. The powder has an apparent density of 3.17 g/cm³ and a true density of 8.01 g/cm³. The experiments were conducted using a laser with a wavelength of 1.064 μm and a maximum power of 300 W. The build platform was moved with a resolution of 10 μm, and the powder layers were deposited using a roller. The building stage was placed in a vacuum chamber to prevent oxidation. The study examined thermal deformations, including the temperature gradient mechanism (TGM), which causes bending due to temperature differences. Different scanning strategies were tested to minimize deformation, with successive scanning being more effective than the least heat influence (LHI) method. The study also investigated the balling effect, which occurs when molten material does not wet the substrate, leading to rough surfaces and lower density. The vaporization effect was also studied, where high laser power and scan speed reduce balling and improve part density and strength. The results showed that pulsed laser operation with high peak power reduces balling and improves mechanical properties. The maximum bending strength achieved was 630 MPa at a density of 91%. The study concluded that optimizing process parameters is crucial for achieving high-quality SLM parts.