In this paper, a new technology of direct and rapid thick coatings fabrication with hybrid plasma-laser deposition manufacturing (PLDM) technology is advanced which is also suitable for functional prototyping and tooling applications. It emphasizes on the influence of laser to the microstructure of coatings and physical properties of surface layers. Unlike the direct rapid plasma deposition manufacturing (PDM), in hybrid plasma-laser deposition manufacturing, the laser beam enters into plasma arc beam and focuses on the molten pool as assisting heat energy. A 280 W pulsed Nd:YAG (yttrium-aluminum garnet) laser machine is used to inspect the effect. The experimental results show that the laser beam could improve the surface state; the elements distribution of coatings deposited by PLDM was even; the physical properties of surface coatings fabricated with PLDM were better than that deposited by PDM. (c) 2005 Elsevier B.V. All rights reserved.