The remanufacturing process is considered a technology that can reduce manufacturing costs and materials. In thispaper, we propose an effective remanufacturing process for repairing gear teeth via direct energy deposition (DED)using SUS316L powder. After a bulky shape is built via DED on the broken tooth, a wire-cutting process is usedto machine the tooth into a precise net shape. As a result of the microhardness measurement, the highest localhardness is found in the heat-affected zone and the near-wire-cut surface has approximately 9% higher hardness thanthe inside of the gear. Each local elastic modulus of the remanufactured gear was calculated based on the measuredhardness data, and finite element analyses are conducted to evaluate the mechanical integrity of the repaired gear byconsidering local material properties. This study confirmed that the remanufactured gear exhibits a lower strain thanthe original gear owing to the increase in local hardness. Therefore, the proposed remanufacturing process can beutilized to repair industrial metal parts.