Metal additive manufacturing (AM) has revolutionized the fabrication of complex geometries, with the laser powder-based directed energy deposition (LP-DED) process emerging as a particularly promising technique. LP-DED enables rapid layer-wise coating, repair, and fabrication of metal parts, supporting both single-material components and functionally graded materials. However, despite its advantages, LP-DED faces significant challenges in maintaining geometric accuracy and melt pool stability due to complex interactions between process parameters, repeated rapid heating and cooling cycles, and heat accumulation. These factors contribute to variations in clad width and height, residual stress formation, and limits productivity—ultimately limiting the broader industrial adoption of LP-DED. A major challenge in LP-DED is the accumulation of heat over multiple layers, leading to inconsistent melt pool geometry and deviations in clad dimensions. As layers build up, the retained thermal energy alters the clad width and height, resulting in geometric errors and potential part deformation. Furthermore, instabilities in the powder flow rate (PFR), influenced by the inert gas flow and dynamic movement of the deposition head, can lead to over- or under-built layers, affecting the standoff working distance between the tip of the nozzle to the melt pool, causing failed deposition due to the clad height deviation from the programmed height. Additionally, excessive material waste and inefficient machine utilization contribute to high costs. Residual stress (RS) formation further complicates the process, as high tensile RS can induce surface and subsurface cracking in LP-DED-fabricated parts. This research addresses these challenges by developing a real-time closed-loop energy and geometry control system to enhance the quality and productivity of LP-DED. The primary research questions explored include whether clad geometry can be effectively controlled while increasing productivity and whether such a control system adversely affects residual stress distribution in the as-built parts. To answer these questions, a comprehensive real-time control methodology is proposed, integrating energy fluence and powder fluence management to optimize clad geometry, deposition efficiency, and residual stress outcomes. The first component of the proposed control system is the Productive Energy Fluence (PEF) module, which dynamically adjusts the deposition head feed rate (FR) or laser power (LP) to regulate clad width and temperature. Initially, an FR-based energy control strategy is employed to enhance productivity by increasing both FR and PFR while maintaining stable median layer temperatures. When FR adjustments reach their limit, the system transitions to an LP-based control strategy, modulating LP to stabilize temperature and geometric accuracy with minimal laser power variations. The second component, the Quality Powder Fluence (QPF) module, utilizes a feed-forward layer-by-layer and segmented height control strategy to adjust PFR, ensuring target clad height and flatness are achieved across multiple layers. Residual stress in the as-built thin wall samples, fabricated using either PEF or QPF modules, is assessed using neutron diffraction to examine the impact of these control strategies on stress distribution. Experimental validation using step-thin walls and high-aspect-ratio thin walls demonstrated that the proposed control system using PEF and QPF modules significantly improves geometric accuracy and reduces production time. Comparative analysis between a hybrid control strategy, single LP-based and FR-based strategies, and an uncontrolled process highlights the superior performance of the proposed approach. Additionally, residual stress measurements indicate that neither the PEF nor QPF module negatively impacts part quality. Instead, the QPF module shifts stress along the building direction (σzz) from tensile to compressive, while the PEF module minimizes stress variations and transitions residual stress to a more favorable compressive state. This research establishes a comprehensive control framework that enhances the geometric precision, productivity, and energy management of LP-DED without negative impact from residual stress. The findings contribute to the advancement of adaptive process control strategies, paving the way for more efficient and cost-effective AM solutions. By addressing key challenges in DED, this study provides a foundation for broader industrial adoption and future developments in intelligent manufacturing systems.