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Selective laser melting (SLM) is an advanced rapid prototyping or additive manufacturing technology that uses high power density laser to fabricate metal/alloy components with minimal geometric constraints. The SLM process is multi-physics in nature and its study requires development of complex simulation tools. The purpose of this paper is to study – for the first time, to the best of the authors’ knowledge – the electromagnetic wave interactions and thermal processes in SLM based dense powder beds under the full-wave formalism and identify prospective metal powder bed particle distributions that can substantially improve the absorption rate, SLM volumetric deposition …