The gas atomization process used for metal powder production has been studied using a low melting point metal: tin. The influence of two experimental atomization parameters (gas flow rate and gas pressure) and the possibility to preview the particle mean diameter with the Lubanska equation are investigated. The ability of spray processing to control and produce well defined metal powders with both the desired particle size range and shape is discussed. (c) 2007 Elsevier B.V. All rights reserved.