In this article, a porosity model is developed based on particle packing theory, fluid mechanics, and particle thermal and dynamic behavior during spray forming. According to this model, the amount of porosity in as-deposited materials can be estimated on the basis of the average fraction of solid in the incident spray and the solid particle packing density. A porosity coefficient ⌽ is introduced. By using this model, the effects of deposition distance, atomization gas pressure, melt flow rate, and melt superheat on porosity are investigated. The amount of porosity demonstrates distinct V-shaped variations with the processing parameters. Finally, the optimal processing parameters for achieving low porosity are discussed on the basis of the calculated results.