Objective The laser fabrication of Ti6Al4V (TC4) alloy in an atmospheric environment is susceptible to nitrogen (N) and oxygen (O); consequently, defects such as cracks can occur because of the induced embrittled nitride and oxide phases. Therefore, the industrial application of LDED (laser direct energy deposition)- treated titanium alloy components has been severely hindered by the limited space and high cost in the closed environment. In this study, a novel nozzle with a protective hood was designed for the laser additive manufacturing of TC4 alloys to alleviate the adverse effects of N and...