Juliana Jumadi, Mohd Shamil Shaari, Muhammad Hafidz Fazli Md Fauadi, Rajan Kumaresan, Agung Premono, Kuldeep K. Saxena, Kumaran Kadirgama, Wan Sharuzi Wan Harun
Selective Laser Melting (SLM) of stainless steel has become a disruptive route for creating complex functional metallic elements by Additive Manufacturing (AM). However, the relationship by which the processing conditions lead to microstructure development and the resulting mechanical and functional properties have been reported across various studies. This article aims to critically synthesize the state-of-the-art SLM-processed stainless steels and particularly emphasize how laser power, scan speed, hatch spacing, and layer thickness dictate the processability window and defect-forming mechanisms. This manuscript reviews the leading routes to characterization, including microstructural analysis, mechanical testing, and corrosion/functional tests, to establish general trends and methodological shortcomings. A detailed study of the process–microstructure relationship has shown that during rapid solidification, which compels the formation of fine cellular structures, a strong crystallographic texture and anisotropy are obtained, which control the strength, hardness, residual stress, and fatigue behaviour. Mechanisms for counteracting the limitations discussed above, including heat treatment, hot isostatic pressing, and advanced surface modification, were critically reviewed with regard to their potential for reducing porosity, microstructure homogenization, and performance enhancement. This review presents an integrated, cross-disciplinary synthesis of processing variables, microstructural signatures, and performance metrics onto a single unified platform to offer a consolidated view that relates defect formation physics with texture evolution rates as well as posttreatment interventions across multiple SS grades. This method facilitates the recognition of interdependencies that are not described concurrently in current studies and steers a rational optimization strategy for SLM settings. The review concludes by pointing out the insufficiently solved research sectors, such as the development of standardized testing processes, system defect control, and multiscale modeling. In addition, it suggests further routes to optimize SLM stainless steels for high-end structural applications. © The Author(s) 2026.
Automotive Engineering Centre, Universiti Malaysia Pahang Al-Sultan Abdullah, Pekan, Pahang, 26600, Malaysia; Faculty of Mechanical & Automotive Engineering Technology, Universiti Malaysia Pahang Al-Sultan Abdullah, Pekan, Pahang, 26600, Malaysia; Faculty of Artificial Intelligence and Cybersecurity, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia; Composite Research Group, Department of Mechanical Engineering, Durban University of Technology, Durban, South Africa; Department of Mechanical Engineering, Universitas Negeri Jakarta, Jl. Rawamangun Muka, Jakarta, 13220, Indonesia; Department of Mechanical Engineering, Galgotias University, Uttar Pradesh, Greater Noida, 203201, India
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