The ever increasing sustainability and business requirements drive product lifetime extension by Repair & Remanufacturing (R&R). Directed energy deposition (DED) metal AM allows efficient means of adding new material in worn or damaged locations and introducing new structural and/or functional features in existing or new design, resulting in metal component performance revival at moderate cost. Manual robot programming and quality assurance (QA) in manufacturing are labor-intensive and error-prone, posing challenges for DED in advanced manufacturing and R&R. Sophisticated process control required for high quality products raises the ambition level even higher. SMART-DED project addresses these challenges by adaptive AI-driven control systems for simultaneous process and robot motion control, leveraging multi-modal sensor data and digital manufacturing resources. User-friendly LLM-powered interfaces and scalable AI models will simplify offline programming and enable precision QA for diverse components. Intelligent DED processes thermal management is the key issue in true adaptive process control and the basis for detecting defect formation in-situ and triggering the corrective actions adaptively. SMART-DED demonstrates the results of these efforts to establish sustainable, efficient, and fully automated solutions for industrial R&R applications.