The invention provides a discharge lamp with uneasily damaged glass shell and a manufacturing method thereof. The discharge lamp comprises a glass shell (1), a metal body (31) covered on the glass shell (1) and a solder layer (32) between the metal body (31) and the glass shell (1). The glass shell (1) and the solder layer (32) are not fixedly connected. Compressing deformation alpha caused by the metal body (31) is formed in the circumferential direction of the glass shell (1). Stress value of the compressing deformation alpha is 6kgf/cm<2>, ideally less than 40kgf/cm<2>.