<p>Binder jetting of cobalt-chromium-molybdenum (CoCrMo) alloy offers significant potential for producing complex biomedical components, but achieving consistent part quality requires a thorough understanding of the multi-parameter optimization of binder jetting process. This study presents a systematic optimization of eight key parameters for gas atomized CoCrMo powder using a Taguchi L₂₇ orthogonal array. The results demonstrate that recoat speed was the most dominant factor for part strength and surface finish, causing a 57 and 73% change in their respective response measures. In contrast, dimensional accuracy was highly anisotropic: drying time was the primary driver for Z-axis error (Δ = 0.10 mm), while drying power and roller traverse speed controlled X–Y fidelity. A critical trade-off was identified, where the parameters that improved green density (e.g., drying power, Δ = 1.34%) also exacerbated Binder Bleeding and Layer Shifting. The innovative aspect of this work is the simultaneous consideration of all key parameters for optimization, rather than fixing some and varying only a small subset. Approaches that tune only a few parameters limit our understanding of the role of less-studied factors such as drying time, recoat speed, and roller rotation speed on geometric accuracy and part integrity. The findings provide a quantitative framework for optimizing binder jetting, highlighting that powder spreading mechanics and thermal management are the primary levers for controlling green part quality.</p>