NiCoCrAlY coatings are widely used in aerospace industries and gas turbines due to their exceptional resistance to high-temperature oxidation and corrosion. Despite this significance, the quantitative analysis of the influence of laser cladding process parameters on the geometrical characteristics of these coatings, particularly using sensitivity analysis methods, remains a research gap. In this study, the effects of laser power, duty cycle, and scanning speed on the coating height, width, angle, and dilution produced by laser cladding were investigated. For this purpose, a fiber laser with a maximum power of 1 kW was utilized. RSM developed regression models, and ANOVA confirmed that the models were significant, with a high R² and a non-significant lack of fit. The results of Sobel sensitivity analysis revealed that scanning speed has a dominant effect on height, angle, and dilution, contributing more than 80% (88.8%, 80.7%, and 81.8%, respectively). In contrast, laser power exhibited a minor to moderate influence (3.9%, 16.3%, and 13.3%, respectively), while the duty cycle, with contributions of 7.3%, 3%, and 4.9%, was the least significant control parameter for these three output responses. For coating width, laser power (51.3%) was more than twice as influential as duty cycle (25.8%) or scanning speed (22.9%). The complete consistency in the ranking of effective factors between the Sobel method and RSM confirms the validity of the results. This study demonstrates that Sobel sensitivity analysis, by quantitatively decomposing the contribution of each parameter, serves as a powerful tool for the optimal design of the laser cladding process.