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• A novel cable-type wire-based arc additive manufacturing was employed for the first time to fabricate Fe 3 Al intermetallic. • The Fe 3 Al thin wall presents coarse columnar grains with epitaxial growth. • The microhardness is higher in the top region of the Fe 3 Al thin wall. • The Fe 3 Al prepared via CWAAM demonstrates superior compressive strength. A novel arc additive manufacturing process using cable-type wire (CWAAM) was successfully used for the first time to fabricate Fe 3 Al intermetallic with 33 at% aluminum content. The microstructure and mechanical properties of the in situ prepared Fe 3 Al alloy were evaluated through optical microstructural characterization, X-ray diffraction for phase analysis, electron dispersion spectroscopy for chemical composition analysis, hardness testing, and compression testing. The results indicate that compared with Fe 3 Al alloy prepared by traditional sintering or mechanical alloying methods, the Fe 3 Al alloy prepared by CWAAM exhibits relatively uniform distribution of alloying elements and higher compressive strength. [ABSTRACT FROM AUTHOR]