The metal spray forming process was examined using mathematical simulation and verified through the prototyping evaluation at Baosteel’s test and development facilities.The mathematical model comprised of four sections,including jet gas flow in the deposition chamber;single droplet behavior along its trajectory path;probability and statistical analysis of droplet mass behavior,and forecast of the shape and temperature distribution of the billet during the spray forming process. The metal spray forming process was examined using mathematical simulation and verified through the prototyping evaluation at Baosteel’s test and development facilities. Mathematical model comprised of four sections, including jet gas flow in the deposition chamber; single droplet behavior along its trajectory path; probability and statistical analysis of droplet mass behavior, and forecast of the shape and temperature distribution of the billet during the spray forming process.