This study explored the discrete element method to model the Inconel powder flow through the laser head nozzles. The laser head was modeled with four nozzles. Bi-particulate powder flow simulations were carried out using discrete element modeling through LIGGGHTS open-source software. Then, the temperature distribution on the powder particles on the base plate was captured using finite element simulations using COMSOL. © 2023, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.