Abstract: During the SLM forming process, the tooth profile support structure in contact with the new spherical gear tooth surface affects the tooth surface forming accuracy. In this paper, the Simufact simulation software is used to simulate the SLM forming process of spherical gears. Using BBD's response surface analysis method, the average deformation of the tooth surface is used as the evaluation index. Through the establishment of a parameter analysis and optimization model, the width of the tip of the teeth, the spacing of the teeth and the hollow are studied. The influence of the three tooth profile parameters on the average deformation of the tooth flank determines the optimum level for each element. As a result, the significant impact of each factor on the mean strain is addendum width>dendum root width>tooth spacing. The optimal combination of tooth shape structure parameters is determined as tooth top width 1.0 mm, tooth spacing 0.71 mm, tooth root width 1.0 mm, and the optimization results meet the requirements.