Image analysis is an ideal tool for characterizing the size and shape distributions of atomized metal powders. The manufacture of complex shaped metal parts by Metal Injection Molding (MIM) is a growing industry. The shape and size of metal powders play an important role in determining process efficiency and properties of the final MIM components. Spherical powder particles are typically favored by MIM manufacturers looking to achieve best tolerances and properties in final components. Therefore, it is important to monitor atomized powder to ensure that particles of the desired shape and size are produced.