Intensive processing optimization of Zn-Cu fabricated by laser powder-bed fusion

• Single-track experiments reveal that increasing scanning speed refines grain structure but deteriorates formability, leading to defects in multi-track fabrication. • Optimal processing parameters produce Zn-Cu alloy with high density and excellent mechanical properties: tensile strength of 157.13 MPa, yield strength of 106.48 MPa, and elongation of 14.7%. • LPBF of Zn-0.8Cu offers significant advantages for custom-designed biodegradable bone implants, addressing issues of spheroidization and formability. • This study provides comprehensive insight into the microstructure evolution and processing optimization of LPBFed Zn-Cu alloys for biomedical applications.