SKD61 – a common tool steel with high temperature and high-pressure resistance, is largely used in manufacture of stamping and casting molds. However, mold components often suffer from cracking, deformation, and wear overtime. Wire arc additive manufacturing (WAAM) technology is an innovative technique suitable for both the manufacture and repair of mechanical parts. The current research investigates the effect of process variables on the geometry of weld beads in WAAM of SKD61 steel, focusing on the impact of factors such as travel speed v and electrical current I on shape and size of single weld beads. The outcomes show that process variables have considerable effects on morphology as well as the dimensions of weld beads (height and width). This research provides valuable information, helping to select suitable process variables for the deposition of SKD61 steel by WAAM.