This study investigates the effects of laser power, scanning speed, and powder feeding rate on the aspect ratio of the cladding layer using TC4 powder as the feedstock. A mathematical model correlating process parameters with the aspect ratio is established based on response surface methodology, and optimal process parameters are determined. The results show that the laser power and powder feeding rate had great influence on the aspect ratio of cladding layer. The aspect ratio of cladding layer is proportional to the laser power and inversely proportional to the powder feeding rate. The optimized laser cladding parameters found to be a laser power of 2 500 W, scanning speed of 14.42 mm/s and powder feeding rate of 0.6 r/min. Verification experiments showed good macro-morphology quality of the cladding layer, with a prediction error of only 3.7% when compared to actual values.