The feasibility of fabricating the tetrapod-like zinc oxide (TZ) nanoparticles with a DC thermal plasma reactor was demonstrated in the present study. Advantages of this process include the low cost and high yield rate (0.8-1.0 kg/h) in producing high TZ content mixtures (with small portion of rod-like zinc oxide (RZ) and plate-like zinc oxide (PZ) nanoparticles) from commercial metal zinc powders. ZnO nanopowders with high TZ content could be employed as the starting material for photocatalytic filters. The ratio of TZ to RZ and PZ in the products was observed to be strongly influenced by the plasma power and the plasma gas flow rate. The optical spectrum, photostability and anti-microbial property of the as-grown and annealed TZ mixtures were examined and compared in this study. (C) 2009 Published by Elsevier B.V.