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Additive manufacturing (AM) produces near-net-shaped parts directly from a 3D-CAD model in a layer-by-layer manner. One of the most common AM technique for fabricating metallic components is powder bed fusion (PBF). The PBF process has shown great potential in fabricating metallic parts with properties better or comparable to conventional methods. However, there are some challenges in reproducibility, process stability, robustness, etc. This thesis elaborates on several of these challenges and addresses the influences of feedstock material, build orientation and part design on the final outcome. The PBF process uses fine metal powder as feedstock material and in order to have an economically feasible process, powder recycling is a necessity. However, to ensure a robust process and consistent material properties, the feedstock material need to be handled with caution as powder properties will affect the …