Abstract
This study presents a conceptual design and analysis of an additive manufacturing system based on the Selective Laser Melting (SLM) process, with a focus on the optimization of process parameters and thermal behavior. The research addresses the critical challenge of achieving stable melting conditions, minimizing defect formation, and ensuring high mechanical performance of fabricated components. An integrated framework combining system architecture, process parameter analysis, and thermal modeling is proposed. The influence of scanning speed and energy density on mechanical properties, porosity, melt pool characteristics, and residual stress is investigated. The results demonstrate that optimal process conditions, particularly within a scanning speed range of 600-800 mm/s and energy density of 60-90 J/mm³, provide a balanced combination of strength, ductility, and structural integrity. Thermal field analysis reveals the presence of localized heating, steep temperature gradients, and heat accumulation effects, which significantly influence microstructure formation and process stability. The findings confirm that controlled energy input and optimized thermal conditions are essential for reducing defects and improving the quality of SLM-produced components. The proposed approach is particularly relevant for the production of defense-oriented metallic components requiring high reliability and structural integrity. The study provides a theoretical basis for further experimental validation and practical implementation in advanced manufacturing systems.