Direct Metal Laser Sintering (DMLS) is an emerging additive manufacturing process with the capability to manufacture small parts with complex geometries which otherwise cannot be produced by subtractive manufacturing techniques. Most components produced by DMLS are fully dense and have mechanical properties that are comparable to wrought material. In order to increase the use of DMLS, it is critical to expand the number of qualified powders from twelve to produce a wider range of alloys for DoD (Department of Defense)-centric applications. Development of low-alloy high-strength steels for the DMLS process will increase the applications of this technology for the DoD to support readiness, repair and maneuverability. For this study, a DMLS 'recipe' for a new metal powder was created by adjusting machine parameters (i.e. hatch distance and laser scan rate) in an effort to produce a fully dense structure with excellent mechanical properties. Microhardness and microstructure analyses were used to investigate the effects of the machine parameters on the quality of the steel component.