Additive manufacturing offers potential for functional integration, free-form surfaces and channel structures for the development of innovative hy-drogen burners. However, the proclaimed design freedom in laser-based powder bed fusion of metals (PBF-LB/M) is limited regarding downskin surfaces 45° with respect to the build platform when employing standard process strategies. In order to prevent manufacturing defects or the necessity of support structures, an alternative approach was pursued focusing on process parameters and scan patterns. Their influence on the manufacturing quality of 316L specimens with gradually increasing overhangs was investigated experimentally before the find-ings were applied to complex parts. The orientation of scan vectors towards overhanging surfaces allowed for support-free swirl vanes with downskin an-gles of 23.5°. Tailoring the process strategy to geometric features combined with the use of optical measurement systems facilitated an iterative design pro-cess of the internal air and hydrogen guidance to optimize the combustion prop-erties of the burner.