Additive manufacturing (3-D printing) is a near-net forming technology. It provides a new way for manufacturing high quality blanks of thin-wall titanium alloy parts. However, in the forming process of thin-wall parts, deformation and residual stress will affect forming quality and subsequent processing of the specimens. In order to solve this problem, TC4 titanium alloy thin-wall parts were formed by selective laser melting. The effects of laser power, scanning speed, thickness of thin-wall and direction of scanning path on deformation and residual stress of specimens were studied. Surface residual stresses at different depths were measured. The results show that deformation occurs mainly on both sides of the top layer of thin-wall parts. The maximum residual stress is mainly distributed in the bottom and the middle of thin walls. With laser power of 180W and scanning speed of 1200mm/s, the deformation of specimen is the smallest. With wall thickness of 0.6mm and scanning path direction of 45°, residual stress of the specimen is the smallest. Residual stress of the untreated surface of thin-walled parts is larger than that of the inner surface. This research provides technical assistance for the manufacture of high quality thin-wall titanium alloy blanks.