<p>Direct laser metal deposition is a prominent additive manufacturing technology for fabricating complex metal geometries and repairing expensive components. Enhancing the quality and mechanical properties of components manufactured through this process, particularly from titanium-based superalloys, remains a primary research focus. This study investigates the effects of trochoidal-shaped scanning patterns and parameters—including path shape, path width, step-over distance, and scanning speed—on the build quality of Ti-6Al-4V layers. A Taguchi Design of Experiments approach was employed to evaluate the impact of process parameters on critical responses such as substrate deformation, surface flatness, useful area ratio, powder catchment efficiency, and defect formation. The signal-to-noise ratio and analysis of variance were performed to analyse the significant contribution of each parameter. It was found that adaptive-shaped trochoidal paths improved substrate deformation and surface flatness, with narrower path width providing the best results. A shorter step-over distance maximized the useful area ratio, while faster scanning speed gave higher surface flatness and defect-free layers. The optimal parameter combination—adaptive shape, 9 mm path width, 1 mm step-over distance, and 400 mm/min scanning speed—resulted in crack-free layers, 63.16% less substrate deformation, 91.40% better surface flatness, and a 20.70% higher useful area ratio compared to conventional straight patterns. However, the powder catchment efficiency of trochoidal path was slightly lower, suggesting an area for improvement. These findings highlight the potential of trochoidal tool paths in improving the quality and reliability of high-performance parts manufactured via DLMD, contributing to advancements in its adoption for aerospace and marine industries.</p>