Selective Laser Melting (SLM) offers high resolution, high density, and expanded design freedom, making it an ideal technique for weight sensitive structural applications. However, specific geometries, such as overhang features, lattice structures, and hollow members, not only complicate the fabrication process but also compromise the structural integrity as these features are susceptible to subsurface porosity, residual stresses, and high deformations. Current design methods either lack the ability to control these defects or are computationally infeasible. This study aims to provide a Design of Experiments (DOE) based approach to design an aircraft engine bracket. The initial design process involves an analysis of the localized geometric features critical in determining the part quality. These features are included in a DOE study to obtain a response surface for the studied defects. Further size and shape optimizations are then performed to minimize the influence of SLM induced defects on the part quality.