Abstract: This study aims to achieve the high-quality fabrication of corrugated honeycomb structures with both thin-walled and curved surface characteristics, which exhibit multi-directional load bearing and energy absorption capabilities, via selective laser melting (SLM). First, as the key point in forming the honeycomb structure, the wall thickness of the corrugated honeycomb is controlled, and laser power and scanning speed are the key parameters to determine the appropriate range of wall thickness. 316L stainless steel is used as the material for the corrugated honeycomb to carry out single-track molten pool simulations and tests. A single-track molten pool experiment was conducted, and the accuracy of the single-track molten pool simulation was verified by measuring and comparing the key parameters of the molten pool (such as depth and width). According to the results of the single-track molten pool simulation and test, the range of laser power and scanning speed suitable for corrugated honeycomb forming was preliminarily determined. Second, forming experiments of the corrugated honeycomb unit cell were carried out with different laser powers and scanning speeds. Subsequently, further tests were conducted on the formed honeycomb unit cell samples through mechanical compression tests and wall thickness measurements. Based on the test results, different laser powers and scanning speeds were analyzed and screened to determine the range of laser powers and scanning speeds suitable for producing the 0.1-mm-thick honeycomb wall. Third, aiming at deformation control during the corrugated honeycomb forming process, further optimization was carried out within the selected parameter range. A simulation model of the honeycomb unit cell was established to simulate the overall deformation of the corrugated honeycomb during the forming process. Before conducting the analysis, three calibration parameters were obtained through standard parts, ensuring the accuracy of the forming simulation model. Using the calibrated model to simulate corrugated honeycomb forming, the average deformation of the inner and outer sides of the honeycomb unit cell was taken as the evaluation index. Based on the determined ranges of laser power and scanning speed, combined with layer thickness and baseplate temperature, a four-factor three-level orthogonal experimental design was implemented. Based on the results of the orthogonal experiment and considering the influence degree of baseplate temperature on specimen forming, the optimal parameters suitable for corrugated honeycomb forming were determined as follows: laser power 120 W, scanning speed 900 mm·s^–1, layer thickness 40 μm, and baseplate temperature 30 ℃. After the process parameters were determined, the corrugated honeycomb was fabricated, and a hexagonal honeycomb of the same thickness was formed. Compression tests were conducted to evaluate the mechanical properties of the formed corrugated honeycomb by comparing its load-bearing capacity and energy absorption indicators with those of the hexagonal honeycomb under different compression directions. According to the results, it can be concluded that the corrugated honeycomb achieved high load-bearing levels in both out-of-plane and in-plane directions, and it possessed load-bearing and energy absorption characteristics in multiple directions, meeting the design goals. This study provides a basis for the high-quality fabrication of thin-walled honeycomb structures with complex surfaces via SLM.