Selective laser sintering (SLS) is an additive manufacturing process that yields excellent part qualities with good mechanical properties. This process employs micron-sized polymer particles, which are selectively fused by a laser. While there seem to be hardly any boundaries regarding design, there are quite some restrictions concerning the variety of commercially available SLS materials. At the moment, the most widely used polymeric material for SLS is polyamide 12 (PA12), with a market share of roughly 95%. In order to broaden the field of application of SLS, novel polymer powders with good handling properties are needed. The polymer particles need to be optimized regarding size, shape, flowability and packing characteristics. In this contribution novel melt emulsification [1] and precipitation processes are discussed. Bulk polymer materials are directly converted to spherical micron sized particles in a single unit operation. The produced particles are characterized regarding their size and morphology via electron and light microscopy. Furthermore, also crystallinity, structural characteristics and flowability are analyzed and the product properties are correlated with process parameters. This way, we show the potential of these processes for the production of novel easy-to-handle polymer particles for SLS. References [1] Fanselow, S.; Emamjomeh, S. E.; Wirth, K.-E.; Schmidt, J.; Peukert, W., Production of spherical wax and polyolefin microparticles by melt emulsification for additive manufacturing. Chemical Engineering Science 141 (2016) 282–292.