This paper examines the factors that effect the efficiency of the CO sub 2 -laser powder cladding process. By theoretical calculation and experimental work it has been possible to identify how much of the original laser energy contributes to the cladding process and how much is lost to the surrounding environment by reflection, radiation, convection etc. Every aspect of energy redistribution has been analysed and quantified and this has lead to a deeper understanding of the process. The paper concludes with a number of suggestions for improving the efficiency of blown powder laser cladding