Centimeter-sized samples of hypereutectic Al–15 mass% Fe alloy were manufactured by a laser powder bed fusion (L-PBF) process while systematically varying laser power (P) and scan speed (v). The effects on relative density and melt pool depth of L-PBF-manufactured samples were investigated. In comparison with other Al alloys, a small laser process window of P = 77–128 W and v = 0.4–0.8 ms⁻¹ was found for manufacturing macroscopically crack-free samples. A higher v and P led to the creation of macroscopic cracks propagating parallel to the powder-bed plane. These cracks preferentially propagated along the melt pool boundaries decorated with brittle θ-Al₁₃Fe₄ phase, resulting in low L-PBF processability of Al–15%Fe alloy. The deposited energy density model (using P·v^−1/2) would be useful for identifying the optimum L-PBF process conditions towards densification of Al–15%Fe alloy samples, in comparison with the volumetric energy density (using P·v⁻¹), however, the validity of the model was reduced for this alloy in comparison with other alloys with high thermal conductivities. This is likely due to inhomogeneous microstructures having numerous coarsened θ–Al₁₃Fe₄ phases localized at melt pool boundaries. These results provide insights into achieving sufficient L-PBF processability for manufacturing dense Al–Fe binary alloy samples.