Wire Arc Additive Manufacturing (WAAM) process is an innovative method for producing metal parts layer by layer. In this study, the metal active gas (MAG)-WAAM technique is used, with ST37 as the substrate and ER70S-6 as the deposition material. While key parameters such as torch angle, gas flow rate, and electrode-to-workpiece distance remain constant, travel speed and voltage are varied at three levels using a full factorial design to analyze their effects. The research focuses on geometric and dimensional properties, particularly wall height and width, using Analysis of Variance (ANOVA) to determine significant relationships. The study identifies significant relationships between the input parameters and the wall geometry. Results indicate that travel speed influences wall height by 69.6% and weld width by 85%, underscoring its critical role in achieving high-quality deposits. Voltage, on the other hand, showed a lesser effect, accounting for approximately 1% of the variations. This limited influence is attributed to the narrower range of voltage variation compared to travel speed. The main challenge is optimizing parameters to prevent defects like deformation and overlap, ensuring the efficiency of the MAG-WAAM process for large, complex metal parts.

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