Abstract: A 2D transient mathematical model was developed to investigate plasma powder deposition shaping process, presenting the free surface evolution of multilayer and the simulation of fluid flow and heat transfer.The Level-Set approach was adopted to deal with some factors such as deposited track, liquid/vapor interface, which considered surface tension gradient (the major driving forces for the melt flow), interface curvatures, buoyancy and convection heat loss.The SIMPLEC algorithm was used for solving the governing equations.The results obtained by the simulation were in agreement with those measured in experiment, and the effect of the deposition process parameters such as input current, scanning velocity and powder feeding rate on the profile of deposition layer and shaping quality was analyzed.