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 0-53 mu m can be produced by atomizing the more crystalline polymer, using a 3.175-mm melt stream size at 205 degrees C. Using the GAP in an alternative route to mass producing powders from low-molecular-weight, polyethylene-based waxes that cannot be ground eliminates most of the problems of 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 fashion.