<p>Direct metal laser sintering (DMLS) is an emerging additive manufacturing technology used to produce high-strength alloys with good corrosion resistance. This study explores the simultaneous impact of laser power, scanning speed, hatching space, and scanning direction angle on the mechanical and surface properties of DMLS-fabricated parts. Very limited research has simultaneously considered these parameters in the DMLS process to study the surface characteristics of AlSi10Mg alloys. The fabrication of the AlSi10Mg component was carried out using the Taguchi <i>L</i>₉ experimental plan (four variables with three levels each), and the interaction effects of multi-response variables on part properties were analyzed, which is rarely explored in prior studies. Among all the variables, laser power had the greatest impact, followed by scanning speed, scanning speed direction, and hatching space. Surface roughness was most influenced by the scanning direction angle, followed by hatching space, laser power, and scanning speed. The average micro-hardness was minimal at a 67° scanning direction angle due to the development of a non-uniform thermal gradient and poor cooling rate, leading to coarse grain formation. Additionally, this research uniquely implements multi-response optimization using COPRAS, a novel approach for optimizing the DMLS process in fabricating AlSi10Mg parts. The optimal input parameter levels were determined as laser power = 250 Watts, scanning speed = 800 mm/sec, hatching space = 0.16 mm, scanning direction angle = 0°. Furthermore, the comparison of ANN and MANFIS modeling results adds another distinctive contribution to the DMLS process. Both models produced highly accurate results with a maximum prediction error of less than 1.6%. The prediction accuracy of MANFIS was found to be better than ANN.</p>