This research focuses on revolutionizing the development and optimisation of fusion welding and additive manufacturing (3D-printing) processes through a simulation-based approach. By analysing the stability of oscillating melt pools, we aim to minimize the reliance on costly trial-and-error experiments and shorten the time between design and production. Our high-fidelity computational model represents a wide range of manufacturing technologies and reveals how material properties and process conditions affect complex heat and fluid flow during the process and melt-pool stability. Through numerical predictions and comparisons with experimental data, we demonstrate the robustness of our model across multiple time and length scales. Our innovative approach enhances understanding, reduces costs, and enables exploration of the design space in process development and optimisation.

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