Plasma Metal Deposition (PMD) is a Directed Energy Deposition (DED) method allowing to realise large metallic structures. Wire is used in this case as a feedstock, which is injected into a plasma arc allowing to deposit materials in a layer by layer process. Magnesium is one of the materials which is difficult to handle due to its flammability. Additionally the evaporation of specific alloy elements such as zinc is an issue in the processing. In a first step different wires were assessed and test structures were prepared and analysed in more detail with respect to mechanical properties as well as microstructure. Additionally the impact of different heat treatments on the mechanical performance was analysed. It was demonstrated that magnesium alloy wire (AZ91) could be successfully deposited and structural components could be prepared. Additionally a test structure with a size of almost to 1 meter in size could be manufactured. Additionally Magnesium alloys are sensitive to corrosion and therefore dedicated analysis were made to assess the material characteristics of the additive manufactured components. A summary of the main lessons learned is provided and an outlook is given on the potential and application of magnesium components made by additive manufacturing.