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Additive manufacturing (AM), particularly laser-based powder bed fusion (PBF-LB), enables the production of high-strength, lightweight components made of aluminium alloys such as AlSi10Mg. However, joining these parts via welding remains a significant challenge due to weld seam porosity caused by hydrogen entrapment. This study investigates the influence of PBF-LB process parameters, tungsten inert gas (TIG) welding settings, filler material, and post-weld T6 heat treatment on the tensile strength and porosity of welded AlSi10Mg components. Using two different layer heights (30 µm and 60 µm), plate thicknesses (3 mm and 5 mm), and varying welding conditions, a series of 10 TIG-welded sample groups were fabricated and analysed. Microstructural, hardness, porosity, and tensile tests revealed that porosity is high across all samples (11–19 %). A following T6 heat treatment improved the tensile strength. Higher layer heights and thinner plates led to higher tensile strength of the weld seam, while the addition of filler material showed limited benefits. No other influencing factors or interactions could be found. The results emphasize the need to optimize hydrogen control in the processes, melt pool dynamics, and weld seam geometry to receive reliable joints in lightweight manufacturing of PBF-LB AlSi10Mg parts.