A process for forming an overhang feature without downward facing surface defects in the overhang feature on a part; the process includes laying down a first layer with a first powder material on a build plate; fusing the first powder material with a first power laser beam; laying down a second layer on top of the first layer, the second layer comprising a second powder material having an additive which lowers the melting point temperature of the second powder material; forming an overhang feature from the second layer; and fusing the second powder material with a second power laser beam in the absence of forming the downward facing surface defects in the overhang feature of the part.