In this presentation, the innovative use of Discrete Element Method (DEM) was explored to tackle the challenges of powder densification and segregation in Hot Isostatic Pressing (HIP). By investigating critical factors such as powder size distribution and filling conditions, the research provided groundbreaking insights into optimizing the HIP process. Key findings from simulation experiments highlighted the significant impact of particle cohesion and size distribution on the final material properties, with practical applications drawn from the Clean Sky 2 Joint Undertaking project under the Horizon 2020 program.