The fields of rapid prototyping and tooling, have seen rapid expansion due to the use of techniques such as multiple-layer laser cladding using blown metal powders. So far, however, only CO2 and Nd:YAG lasers have been used commercially, and the potential advantages, in terms of both costs and efficiency, of using a high powered diode laser have not been investigated. Due to the unique beam characteristics of a diode laser, the work done with other lasers in this field cannot be assumed to hold true in this new area. The aim of the present paper is to establish the relationships between input parameters and final material dimensions and properties in the process by using a 1.5 kW diode laser and lateral powder-feed nozzle. The composition, microstructure, dimensions and surface propel-ties of the final samples are compared with the major input parameters. (C) 2003 Elsevier B.V. All rights reserved.