## 1 Introduction  
Additive manufacturing (AM) manufactures objects by progressively layering material according to a digital design. In contrast to conventional subtractive manufacturing, which involves the removal of material from a solid workpiece, AM selectively adds material only where required [1, 2]. Metal AM has increasingly been adopted across high-value industries, including the medical, automotive, nuclear energy, and aerospace sectors [3]. Metal AMprocesses can be classified based on various factors, including material feeding methods, energy sources, and part volume. However, a more structured classification is determined by the form of raw material used and its delivery mechanism within the system. From this point of view, metal AM processes are basically divided into two main groups, directed energy deposition (DED) and powder bed fusion (PBF) systems, which are powder-fed systems [4; 5]. PBF systems include direct metal laser sintering (DMLS), selective laser sintering/melting (SLS/M), and electron beam melting (EBM). These processes use a powder bed as the build platform. SLS, DMLS, and SLM utilize a laser as the heat source, while EBM employs an electron beam. SLS and DMLS are sintering-based processes, whereas SLM and EBM involve complete melting of the powder [6]. DMLS is a laser-based additive manufacturing process that utilizes metal powder to fabricate parts directly during the building process. This technique provides the production of complex metal components with high precision and material efficiency [7]. In additive manufacturing (AM), metal powders are typically characterized by a spherical morphology and a controlled particle size distribution to enhance packing density, improve flowability, and ensure uniform layer deposition, all of which contribute to achieving high mechanical performance and near-full part density. Critical powder characteristics such as morphology, apparent and tap density, chemical composition, flowability, and thermal properties directly affect process stability, melt pool behavior, and ultimately, the structural integrity and quality of fabricated parts [8; 9]. Metal powders used in AM have been extensively analyzed, with emphasis on the need for standardized characterization to ensure process reliability [8]. Moreover, it has been demonstrated that powder morphology significantly impacts the mechanical properties of metal matrix composites fabricated via laser powder bed fusion, where enhanced sphericity and uniformity lead to improved ductility and reduced microstructural defects [9]. Most LPBF research relies on commercially available pre-alloyed powders, with nickel alloy 625, 316L stainless steel, AlSi10 Mg, and Ti6 Al4V being the most used materials [10]. Aluminum alloys are well known for their outstanding strength-to-weight ratio, excellent formability, corrosion resistance, and recyclability. Compared to traditional steel, they enable lighter car parts without compromising strength. Ongoing research continues to enhance aluminum alloys, driving further innovations in sustainable lightweighting for the automotive industry [11; 12; 13]. Among aluminum alloys, AlSi10 Mg is extensively used in additive manufacturing for its excellent weldability, high strength-to-weight ratio, superior formability, thermal stability, corrosion resistance, and diverse post-processing potential [14; 15]. Tool-based micromachining techniques, including micro milling, micro turning, micro grinding, and micro drilling, function similarly to conventional machining, allowing for precise material removal at the microscale. Mechanical micromachining processes offer wide application flexibility and versatility by enabling the production of miniature components with complex shapes, independent of material properties [16; 17]. Despite its potential applications and benefits, the influence of the micro-milling machinability of additively manufactured aluminum alloys remains largely unexplored, highlight a significant knowledge gap for optimizing the machining process [18].