To make metallic parts for manufacturing industries, additive manufacturing (AM) has acquired considerable significance. However, most efforts have concentrated on powder-based techniques, and there remains a dearth of the experimental evidence on the mechanical characteristics and structural behavior of metallic elements produced using wire-and-arc additive manufacturing (WAAM). This article examined the optimal parameters to enable bulk fabrication of thick walls made with a SS410 wire. The objective was to assess the optimized variables utilizing response surface methodology (RSM), followed by the microstructural analysis and mechanical property evaluation. During optimization, the influence of wire feed speed, travel speed, and gas flow rate on bead width and height was determined. Further, the optimized variables resulted in the successful formation of thick walls. Secondly, the microstructural analysis mainly featured the martensite and delta ferrite, with the latter’s percentage increasing with build height. The maximum micro-hardness of 452 HV was obtained at the base of the wall. In addition, the remarkable increases in the standard deviation of micro-hardness represent the great extent of anisotropy in the thick wall. Moreover, the maximum UTS (803 ± 8 MPa) and YS (659 ± 10 MPa) are achieved for the OB sample, which is similar to conventional components. However, the current investigation’s percentage elongation of 5% (max) demands more study before the actual use of the WAAM manufactured SS410 material. Therefore, due to the significant degree of anisotropy and poor percentage elongation, the findings conclude that post-processing is required after bulk SS410 manufacturing.

NiTi shape memory alloys are highly favored in engineering and biomedical realms owing to their unique responsiveness to environmental and external triggers. Laser powder bed fusion (LPBF) stands out as a premier method for additively manufacturing NiTi alloy, offering superior density, intricate geometric versatility, excellent surface finish, and chemical uniformity. This makes LPBF the preferred choice among various additive manufacturing (AM) techniques for NiTi alloy fabrication. The functional and mechanical properties of NiTi alloy are significantly influenced by the AM process parameters. Thus, understanding the interaction of these parameters is crucial for optimizing the final structures of additively manufactured NiTi components. However, the rapid melting and cooling rates inherent in the LPBF process can lead to elevated internal stresses, potentially resulting in issues such as cracking and nickel loss. These challenges can negatively impact the phase transformation temperature of the NiTi alloy. Despite these obstacles, studies in the literature demonstrate that LPBF-produced NiTi components exhibit functional and mechanical properties in line with American Society for Testing and Materials’ standards. As a result, they have found widespread use in biomedical applications, where their stress–strain hysteresis closely resembles that of bone tissues. Moreover, NiTi alloy’s remarkable actuation properties have made it indispensable in high-value engineering sectors such as automotive and aerospace industries. In essence, LPBF has emerged as a pivotal manufacturing technique for NiTi shape memory alloy, offering a pathway to produce components that meet stringent quality standards while unlocking a countless of applications across diverse industries. Despite existing challenges, the literature highlights the development of methods to fabricate NiTi components with the necessary shape memory and superelastic properties without postheat treatment, which can streamline production by lowering cycle time, cost, and duration, alongside research into how anisotropic microstructures impact alloy fatigue behavior under repeated actuations.