Process parameters of laser cladding continue to be the subject of research. Parameter windows are strongly infuenced by the material, the substrate, and the geometry of the printed objects. The results of laser cladding are very dependent on the process parameters. One of the most signifcant parameter sets is the laser power P (W) and the feed rate f (m/s). Their relation is described as linear energy E = P/f (J/m) and it dictates the energy input and therefore the size of the melt pool. Additionally, the amount of  powder  added to the process zone mainly impacts the resulting deposition rate and temperature of the melt-pool. The feed rate of the processing head has an infuence on the process time and the overall volumetric heat input regarding the size of the heat-affected zone and the dilution of the metals. Another main factor is the material used and its inherent properties. These include the melting point, weldability, surface tension of the liquid phase, thermal conductivity, and refectivity/absorption of laser light.

Furthermore, different parameters can become signifcant in specifc circumstances. In situations where heat dissipation is restricted at, for example, quick geometric changes, the type and fow rate of the shielding gas can become critical. The large number of parameters is a challenge for the process development.

For a deeper insight into the process and in search of best parameters, the application of design of experiments is indispensable. As an example, the process parameters for additive manufacturing of iron–nickel powder are shown in Table  1.2. These parameters were found by the use of a statistical screening design and a subsequent full factorial design of experiments.