Selective laser melting (SLM) has emerged as a powerful additive manufacturing technique for creating complex metal parts. However, the high thermal gradients and rapid solidification rates inherent in this technique trigger significant residual stresses within the produced components. These stresses can potentially cause some defects such as cracks and deformation, threatening the structural integrity and performance of the parts. To overcome this challenge, this study employed a new Finite Element Analysis (FEA) feature in Abaqus software was employed in this study. This feature facilitates a more accurate prediction of residual stresses in the SLM-produced Ti-6Al-4V alloy samples under various laser power settings and real-world machine conditions. Simulating the SLM process and capturing the complex thermal and mechanical interactions would enable the researchers to identify the optimal laser power that minimizes the residual stress formation. The findings of this study brought about significant implications for the optimization of SLM processes. Once the factors that contribute to residual stress are identified, manufacturers can adjust process parameters to produce parts with improved mechanical properties and reduced risk of failure. In this regard, this research work is a significant step forward in using simulation to optimize additive manufacturing techniques in various industries.