Abstract: Fe-Ga (Galfenol) alloys have attracted significant attention as next-generation magnetostrictive materials due to their unique combination of large low-field magnetostriction (~400 ppm), excellent mechanical durability, and corrosion resistance. Unlike rare-earth-based magnetostrictive materials, these iron-gallium alloys offer substantial cost advantages and environmental benefits, making them particularly suitable for precision actuators, vibration energy harvesters, and underwater transducers. However, conventional manufacturing methods for Fe-Ga alloys face challenges in achieving complex geometries while maintaining desired magnetostrictive performance. Selective Laser Melting (SLM), a prominent powder bed fusion (PBF) technology, offers distinct advantages including rapid processing cycles, high design flexibility, the ability to fabricate complex geometries, and superior component performance. In SLM processing, energy-related processing parameters such as laser power, scanning speed, and beam spot size that govern the point-wise powder melting behavior-critically determine the resultant microstructure and part quality. Additionally, the discontinuous parameters, including scan spacing, layer thickness, and scanning strategy are geometrically related to scan path and build layers. These factors primarily determine the spatial overlap between adjacent melt tracks and in which, scanning strategy plays a crucial role by modifying melt pool dynamics and thermal gradients, thereby affecting grain structure and mechanical properties. To achieve defect-free Fe-Ga alloys with superior performance through PBF, precise control of both energy-related and geometric parameters is essential. This study presents a comprehensive investigation into the selective laser melting (SLM) process of Fe81Ga19 alloy, combining finite element simulation and experimental validation to optimize process parameters and enhance mechanical properties. A high-fidelity 3D finite element model was developed using ANSYS software, incorporating temperature-dependent material properties, latent heat effects, and nonlinear thermal boundary conditions. The dynamic laser scanning process was accurately simulated using APDL programming with the birth-and-death element technique, enabling precise modeling of the moving Gaussian heat source and layer-by-layer deposition. The research systematically examines the influence of critical process parameters-laser power (80-130 W), scanning speed (800-1200 mm/s), hatch spacing (50-65 μm), and preheating temperature (25-200 °C)-on melt pool characteristics, thermal behavior, and mechanical performance. The key findings reveal that: (1) The melt pool peak temperature increases when laser power rises from 90 W to 110 W, while doubling the scanning speed reduces the melt pool length due to decreased energy input; (2) The cooling rate exhibits a strong positive correlation with both laser power and scanning speed; (3) A novel 67° interlayer rotation scanning strategy effectively reduces thermal anisotropy, minimizing residual stresses compared to unidirectional scanning. Through multi-objective optimization, the study identifies under optimized process parameters (laser power: 105 W, scanning speed: 1200 mm·s?1, hatch spacing: 60 μm, layer thickness: 30 μm, and 67° rotation scanning), the melt pool width and depth reached 138 μm and 61 μm, respectively, with a width-to-depth ratio of 2.26. The as-built sample exhibited a density of 98.67%, while the microhardness and compressive yield strength improved to 310.9 HV and 701.1 MPa, respectively, demonstrating optimal comprehensive mechanical properties. The research establishes quantitative process-property relationships and provides a validated numerical framework for SLM parameter optimization of magnetostrictive alloys, offering significant guidance for industrial applications of Fe-Ga components in smart actuators and sensors.