Laser cladding has been widely used in direct laser fabrication and laser refabrication for metal parts. It is a high precision and complicated process due to multiple process parameters involved. These parameters are strongly tied to each other and their effects are still far from being completely understood. In order to make the optimal choice, a feasible mathematical model is established to describe the interaction between laser and powder particles and to predict and control the cross sectional area. Additionally, analysis concentrating on the effect of the various parameters on the cross sectional area is made. Results show that laser power, powder feed rate, scan speed and radius of focused powder stream are the main factors. Correlations between main process parameters and cross sectional area of an individual clad track have been found. The model also provides predictions of range of process parameters for melting powder to form specific cross sectional area, which will guide the experiment and greatly reduce the cost of the experimental investigations.