The　plasma-spray　coating　was　physically　modeled,　empirically　approximated　and　numerically　simulated　in　Monte　Carlo　method,　based　on　scanning　electron　microscopy　images　of　its　microstructures.　The　impact　of　the　synthesis　conditions,　including　but　not　limited　to　the　size　and　velocity　of　impinging　particles,　nozzle-substrate　distance,　and　nozzle　s　scanning　speed,　on　the　microstructures　of　the　coatings　was　investigated.　The　simulated　results　show　that　the　size　and　speed　of　impinging　droplets　and　nozzle-substrate　distance　significantly　affect　the　surface　roughness　and　porosity　of　the　coatings　with　randomly　distributed　pores.　For　example,　as　the　size　and　velocity　of　the　sprayed　powder　increased,　the　surface　roughness　and　porosity　of　the　coatings　decreased,　being　weakly　affected　at　a　velocity　faster　than　160　m/s.　An　increase　of　the　nozzle-substrate　distance　also　reduced　the　surface　roughness　and　porosity.