A recoater collision prediction and calibration method for additive manufacturing and a system thereof are provided. The recoater collision prediction and calibration method includes the following steps: loading a printing image file to generate a simulated printing object according to the printing image file; performing a process thermal stress simulation on the simulated printing object to obtain a plurality of simulated deformation variables respectively corresponding to a plurality of prediction results of the simulated printing object in a vertical direction on each layer; obtaining an experimental collision height of an experimental printed object; selecting one of the plurality of simulated deformation variables according to the experimental collision height; calculating a recoater tolerance according to the one of the plurality of simulated deformation variables; calibrating a collision risk formula according to the recoater tolerance; and predicting a collision risk value between the simulated printing object and a recoater according to the collision risk formula.