Direct Metal Deposited (DMD) specimens using Inconel 625 were tested for sliding wear and analysed for reliability. In this study, Taguchi's experimental techniques were used to develop L9 orthogonal array using Design of Experiments (DOE). Three different process parameters, coating thickness, load and temperature were selected for manufacturing the components. Sliding wear test was carried out and wear properties was investigated. Two-parameter Weibull method was used for the reliability studies by which reliability was estimated for different wear values of the manufactured components. The distribution plot on reliability was considered as a good design for Weibull analysis. The study shows that Weibull distribution method can be used for describing the distribution of times to wear properties of rapid prototyped components using DMD for functional applications. © 2019 The Authors. Published by Elsevier Ltd.