During binder jet additive manufacturing, the consistency and homogeneity of the employed powder plays a crucial role in the final density and dimensional accuracy of the green part. In this study, Discrete Element Method (DEM) simulations were performed to investigate the influence of roller spreading input parameters (roller speed, traverse speed, geometry, etc.) on the dynamic flow of powder during layer spreading. Via DEM, we examine how different material properties, such as powder morphology, size distribution, surface morphology, and composition, affect the homogeneity and porosity of the spread layer, yielding accurate predictions for the green part’s density and dimensional accuracy. Today, most research focuses on simulating the dispersion of high-quality, evenly sized, clean foundry sand. This study focuses on the flow behavior of locally-sourced, raw earth sand during the spreading process to support remote additive manufacturing.