Laser cladding filler material is introduced in a pattern on a on a substrate by a filler distribution apparatus having a linear or polygonal array of dispensing apertures for uniform distribution in advance of or during a laser beam transferring optical energy to the substrate. The distribution apparatus includes a housing (or assembly of coupled housings) that defines the distribution aperture array and an internal chamber in communication with the apertures that is adapted for retention of filler material. A mechanical feed mechanism, such as an auger, is adapted for feeding filler material from the internal chamber through the distribution apertures. A feed mechanism drive system is coupled to the mechanical feed mechanism, adapted for selectively varying filler material feed rate. The distribution aperture array may be selectively reconfigured to vary selectively the filler material distribution pattern.
