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Laser Direct Metal Deposition (DMD) has been developed as a manufacturing process to deposit coatings on existing materials and proves advantageous in Additive Manufacturing (AM) of complex and precise components. However, it is necessary to carefully determine the proper process parameter combinations to make this method economically viable for industries. The intent of this study is to address enhancement in productivity of laser DMD of stainless steel EN X3CrNiMo13-4. Accordingly, the effects of the main laser process parameters of laser power P, scan speed v, powder flow rate $$\dot{\mathrm{m}}$$ m ˙ , and spot diameter s on track geometries and build-up rate are discussed. The regression analysis is conducted to derive correlations between the combined set of main parameters and deposition rate. The results show a good linear regression correlation of R2 >0.9 for the geometrical characteristic of aspect ratio, dilution, and deposition rate. The constructed processing map, using linear regression equations, presents proper process parameters selection in connection with deposition rate, aspect ratio, and dilution rate.

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