Through using a novel micro-coating metal additive manufacturing (MCMAM) process in this study, the forming characteristics of the multilayer single-pass specimens were investigated. The forming defects including the porosity and the bonding quality between layers were analyzed. Moreover, we also attempted to study the effect of process parameters such as flow rate, deposition velocity, and layer thickness on the forming morphology. Based on the results, the optimization of process parameters was conducted for the fabrication of thin-wall MCMAM. Finally, estimation criteria for the integrity of the interfacial bond were established.