Hot Isostatic Pressing (HIP) is a technique for creating dense, high-strength components from metal powders. This study emphasizes the use of the Discrete Element Method (DEM) to tackle industrial challenges related to powder densification and segregation during the filling process. By simulating the behavior of powders under various conditions, DEM provides insights into how factors like size distribution and particle characteristics influence packing efficiency. Specifically, we applied DEM to analyze Astroloy powder in different states, allowing us to optimize vibration-assisted filling techniques. This approach not only enhances the quality of HIP components but also addresses practical issues faced in industrial applications, paving the way for more consistent and reliable manufacturing processes.