The feasibility of producing homogeneous powder coating formulations without melting is investigated using Solid State Shear Extrusion (SSSE). A detailed comparison between conventional melt extrusion and SSSE processing conditions of identical formulations is accomplished by following the behavior and degree of polymerization during curing. Commercially available polyester and epoxide powder coating premix formulations were processed by SSSE using a Brabender(R) laboratory-scale twin-screw extruder and further pulverized in a ball mill. Calculations based on particle size before and after comminution in single batch ball mill studies indicate a reduction in energy requirements for SSSE during pulverization. Metal coupons were coated with dry pulverized formulations using an electrostatic fluidized bed coating system. The dynamics of curing were followed for a series of bake time exposures. The sol was separated from the gel using Soxhlet methods and characterized by gel permeation chromatography (GPC). A comparison of experimentally determined gel points and gelation dynamics showed general agreement between both processing methods. The critical yield stress, determined from preliminary mechanical testing of modified thick adherend specimens crack-line-loaded in compression, was also determined. Results showed the SSSE process to be equivalent to melt extrusion.