Abstract: Objective Aiming at the problem that existing path planning of wire arc additive manufacturing only focuses on geometric optimization and fails to consider the material anisotropy and structural load-bearing conditions, this study intends to make full use of material properties to improve the mechanical performance of printing structures through path planning innovation, so as to provide support for the lightweight design of structures. Methods A novel path planning method of wire arc additive manufacturing based on stress field distribution is proposed. First, the principal stress trajectory is generated according to the structural boundary conditions, then, guided by this trajectory, the stress streamline is converted into the printing path, realizing the adaptation between path planning and stress field distribution. Results Experimental verification shows that compared with the traditional printing path, the samples fabricated by this method have a Young’s modulus increase of approximately 29.4% in axial mechanical tests, and the mechanical performance is significantly improved. Conclusion The path planning method of wire arc additive manufacturing based on stress field distribution effectively exerts the advantage of material anisotropy, provides a new design idea for the lightweight design of wire arc additive manufacturing structures, and further expands the application potential of wire arc additive manufacturing technology.