A theoretical and mathematical model based on minimum contact area (MCA) is developed to explain the bonding that takes place in the low-pressure gas dynamic spray (LPGDS) process. It is shown that by normalizing this MCA it is possible to compare the relative elastic modulus as a function of porosity. Theoretical predictions of relative elastic modulus are compared against results obtained through acoustic analysis and it is found that the correlation between is dependent on the porosity. For low porosity, the experimental and theoretical results differ substantially, while for higher porosity there seems to be good agreement between the two. To explain this behaviour it is theorized that full adiabatic shear bands (ASB) are created between only some of the particles. The higher porosity causes higher strain in the samples and thus more local deformation of the particles. This, in turn, causes more actual ASB formation. Since the theoretical model assumes full ASB formation, only the higher porosities cause enough strain to have a comparable relative elastic modulus. For the lower porosities, the local strain is less, and some of the bonds will not achieve full ASB formation. For these cases, the relative elastic modulus will be lower than that predicted.