A new gas atomization process (GAP) was explored for mass producing high-quality spherical powders and very high aspect ratio microfibers from molten polymers. The process involves the use of high-pressure (7.6 MPa or 1050 psi) nitrogen gas and a specifically designed nozzle to atomize a molten stream of polymer into fine droplets that cool to form spherical powders. Polyethylene-based powders, ranging in size from 0 to 200 [Mu]m, were efficiently produced in short cycle times by changing a few process control variables such as atomization temperature and polymer melt stream size in a contamination-free environment. The crystallinity of the polymer favored formation of spherical powders. Analysis of the experimental data indicated that the maximum weight fraction of the powders at 0 to 53 [Mu]m can be produced by atomizing the more crystalline polymer, using a 3.175-mm melt stream size at 2050C. A more recent development that attempts to combine the GAP technology with supercritical gas-assisted extrusion technology will be discussed. This new development just mentioned will facilitate atomization of relatively high molecular weight commercial polymers such as polystyrene. Using the GAP in an alternative route to mass producing powders from conventional grinding processes. These benefits of the process together with its flexibility, high throughput, and facile nature can be expected to make it worth considering for industrial processes that must be safe, be capable of mass production, and operate in an environmentally-benign manner. Potential applications of the powders include uses as raw materials for rotational molding, powder spray coating, and for low cost thermoplastic composites and polymer alloys.