Ti6Al4V is the most common used Ti alloy due to its outstanding comprehensive properties. In order to investigate the process of Laser Net Shape Manufacturing (LNSM) with Ti6Al4V, systematic experimental studies were performed with CO2 laser. The process window and transfer functions of the LNSM process were developed. It was shown that the power mass ratio is a critical factor to achieve good geometry and surface finish of LNSM Ti6Al4V part. The 3D Ti6Al4V parts were deposited with good geometry and surface finish with the parameters selected through the transfer functions. The microstructure of deposited Ti6Al4V samples were mainly made up of mixed fine α and β phase, which indicated good comprehensive properties of deposited samples. The testing results show that the tensile properties of LNSM samples are better than casting data and comparable with forging data of Ti6Al4V.

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