Process-inherent high cooling rates and intrinsic heat treatments of additive manufacturing techniques lead to unique microstructures with concomitantly tempting mechanical properties. However, these process-inherent properties also possess drawbacks such as the formation of pores being crucial for the applications of components under fatigue loading. In the present studies, non-optimal feedstock material, i.e., spattered commercially pure iron powder particles, were employed in the laser-based powder bed fusion of metals. After production, the microstructure and defect distribution were analyzed via electron-backscattered diffraction and micro-computed tomography. The mechanical properties were tested under quasi-static loading and fatigued in the low cycle regime and compared to material manufactured utilizing optimal powder conditions. With respect to defect distribution and grain morphology, it was shown that the between the optimal and non-optimal process conditions only slight differences are prevailing, however, under quasi-static loading a different behavior was found. Most characteristically, the specimens built using the spherical powder exhibit a pronounced yield point and a higher strength as compared to the material built from the spattered powder. These differences can be rationalized by microstructural differences with respect to the chemical composition of the initial powders. Based on the analysis of fatigue life, it could be revealed that the specimens built using spattered powder are competitive to the ideal counterparts with respect to stress response and number of cycles to failure. Taking all results obtained into account, the utilization of spattered powders in additive manufacturing is thought to be robustly feasible such that spattered powders can be considered to be qualified for processing.