Purpose　-　This　paper　aimed　to　propose　a　novel　fused-coating-based　additive　manufacturing　(FCAM);　the　study　of　key　process　parameters　and　mechanical　tests　are　performed　to　determine　the　proper　parameters　when　building　metal　components.　Design/methodology/approach　-　Sn63Pb37　alloy　is　deposited　in　an　induction　heating　furnace　with　a　fused-coating　nozzle　to　build　metal　parts　on　a　copper-clad　substrate.　The　process　parameters　including　nozzle　pressure,　nozzle　and　substrate　temperature　and　nozzle　gap　between　substrate　are　analyzed　and　found　to　have　great　influence　on　parts　quality.　The　mechanical　property　tests　between　the　fused-coating　and　casting　parts　are　performed　in　horizontal　and　vertical　directions.　Also,　the　optical　microscopy　images　are　used　to　ascertain　under　which　conditions　good　bonding　can　be　achieved.　Findings　-　A　FCAM　method　is　proposed,　and　the　exploration　study　about　the　manufacturing　process　is　carried　out.　The　critical　parameters　are　analyzed,　and　microscopy　images　prove　the　suitable　temperature　range　that　requires　to　fabricate　metal　parts.　The　mechanical　tests　confirm　that　tensile　strength　of　printing　parts　is　improved　by　20.4　and　11.9　per　cent　in　horizontal　and　vertical　direction　than　casting　parts.　The　experimental　results　indicate　that　there　is　a　close　relationship　between　process　parameters　and　mechanical　properties.　Originality/value　-　This　paper　proves　that　FCAM　provides　an　alternative　way　to　quickly　make　functional　metal　parts　with　good　quality　and　flexibility　compared　with　other　additive　manufacturing　methods.　Moreover,　good　mechanical　property　is　achieved　than　conventional　casting　parts.