Abstract: This article successfully prepared 1J85 permalloy alloy using CMT arc additive manufacturing technology, and the effects of different CMT printing processes on forming, microstructure, and hardness were studied. The results indicate that the printing process affects the shape of the melt pool. The round-trip printed sample has a uniform heat and is symmetrically distributed in the deposition direction. From a microscopic observation, the grain size of the sample produced by round-trip printing has a larger grain size because of a higher heat. Both samples are composed of columnar crystals grown perpendicular to the edge of the melt pool, and the grains contain columnar and cellular substructures. The changes in the hardness of the samples produced by both co-direction and round-trip printing processes are not significant, and the overall hardness of the round-trip printed sample is greater than that of those of the co-direction printed sample because the change of local heat flux produced by round-trip printing can lead to more stress generation. Overall, the round-trip printing process is superior to the co-direction printing process.