Additive Manufacture (AM) is a technique whereby freeform structures are produced by building up material in a layer by layer fashion. Among the different AM processes, Wire and Arc Additive Manufacture (WAAM) has the ability to manufacture large custom-made metal workpiece with high efficiency. A design study has been performed to explore the process capabilities of fabricating complicated geometries using WAAM. Features such as enclosed structures, crossing structures, and balanced building structures have been investigated in this study. Finite Element (FE) models are employed to take the thermo-mechanical performance into account. Robot tool path design has been performed to transfer the WAAM component designs into real components efficiently. This paper covers these essential design steps from a technical as well as practical point of view.