Metal open-cell foam (OCF) has been rapidly growing in diverse applications with its recognised unique properties that build up from its open strut network. Current research focusses on the optimisation of the original OCF 3D model with pore density ranging from 15 to 50 pores per inch (PPI). The optimisation process is to overcome the challenges of small OCF struts for 3D printing. Software of Geomagic Wrap, Fusion 360 and Altair Inspire were successfully utilised to optimise the OCF 3D model while maintaining its structural integrity. The optimised OCF 3D model of 15 PPI (O15), 25 PPI (O25) and 50 PPI (O50) was attempted to be used in fabricating using additive manufacturing (AM) technique via selective laser melting (SLM). The OCF 3D printed (POCF) was successfully fabricated for 15 PPI and 25 PPI (PO15 and PO25) with copper-10tin (CuSn10) powder as printing materials. Subsequently, PO15 and PO25 underwent mechanical testing and microstructural characterisation. The maximum compressive strength, σcomp. of PO25 (27.6 MPa) was higher than that of PO15 (18.9 MPa), suggesting that PO25 is stiffer and less prone to deformation due to a higher number of struts. Similar to the microhardness test, PO25 recorded 214.75 ± 8.98 HV, which is 39% higher than PO15 (154.55 ± 1.48 HV). The scanning electron microscope (SEM) images revealed there are less than 1% differences in strut diameter between the OCF (O15 and O25) and POCF (PO15 and PO25). The POCF displays structural integrity and is broadly competent with the intended design. The findings have established that CuSn10 POCF, produced via SLM, has effectively improved the OCF design and yielded outstanding mechanical outcomes.