Abstract: In this paper,rapid prototyping based on pulsed PAW technology is introduced.The Taguchi method is applied to design single bead forming experiments properly and then multi-group experimental data of weld width and height are obtained.The prediction model of bead geometry is developed by applying BP neural network based on genetic algorithm.It turns out that the model holds high prediction accuracy and generalization ability verified by error analysis and linear regression,which can predict single and multiple beads geometry accurately.