Most studies in additive manufacturing(AM) regarding the microstructure and mechanical properties are performed on sample blocks or test coupons. However, translating that information for designing more complex shapes of the components is challenging due to the intrinsic thermal history of AM in different geometries. Understanding the relationship between geometry and resulting microstructure is essential to achieve high-quality, defect-free components with improved mechanical properties. Anisotropy and heterogeneity in microstructures and, thus, in mechanical behaviour are observed in laser powder bed fusion(LPBF) components due to the varying thermal gradients and cooling rates in different component locations. This results in variations in grain size, phase morphology and crystallographic texture. Furthermore, a significant problem associated with LPBF components is the development of high residual stresses, which can lead to distortions or cracking during component removal from the build-substrate. The geometric intricacies of the deposited component play a pivotal role in shaping the thermal history and temperature gradients during the process, thereby dictating the microstructural and residual stress evolution in the final component. Ti6Al4V has diverse applications, from producing very thin struts to thicker aerospace components. Hence, understanding the microstructural and residual stress evolution in various geometries aids in tailoring the AM process and post-build heat treatments according to the specific requirements. In the present study, an effort has been made to answer a few of these questions by establishing the processing-structure-properties correlations for different Ti6Al4V component geometries. The role of the thickness of the component is studied. Detailed investigations are being conducted to analyze location-dependent microstructures, residual stresses, and mechanical properties for different geometries. Our preliminary finite element simulations indicate significant variations in residual stresses based on location and geometry. In a given component, we have observed a notable variation in residual stress along the thickness, ranging from tensile stress at the surface to compressive stress at the interior of the component