The constantly pursuing progress in metal material processing technology in terms of forming accuracy, energy saving, productivity, and mechanical properties has spawned reforms in metal material processing technology. The recently emerged laser directed energy deposition (LDED) technology (powder based in this work) uses layer-by-layer deposition of materials to prepare prototype parts [1–3]. With the advantages of high geometric flexibility and complexity, low material waste and high manufacturing resolution, LDED has been successfully applied to repair and remanufacture titanium alloys [4], stainless steels [5], nickel-based alloys [6] or other critical materials. These materials are used in a wide range of applications such as in the aerospace and automotive industries, including housings, radiators, and manifolds [7, 8]. These parts often have complex geometrical features such as planar thin-walls, lattice/honeycomb structures, curved-surfaces, and so on.