A recently developed burn-resistant Ti alloy has been used as a model Ti alloy to assess the response of Ti alloys to direct laser fabrication. The microstructure, homogeneity and the thermal stability of laser deposited burn-resistant alloy have been assessed with respect to those obtained by conventional processing routes. Oxygen is one of the most important factors which controls the mechanical properties of Ti alloys and the effect of the oxygen content on the microstructure of the burn-resistant alloy has been examined after laser processing in air, using the argon carrier gas as protection and in a glove box with an argon atmosphere with O
2< 5 ppm. The microstructures observed for these different atmospheres are very different and are discussed in terms of the extent of oxygen pike-up.