Laser powder bed fusion of polymers (PBF-LB/P) is an additive manufacturing process yielding parts of strong mechanical properties. While there seem to be hardly any boundaries regarding design, there are quite some restrictions concerning the variety of commercially available PBF materials. Currently, the most widely used plastic feedstock powder is based on polyamide 12 (PA12), which makes up a market share of around 90%. To widen the field of application of PBF-processed parts, novel plastic powders of appropriate properties are needed. Besides intrinsic material properties like melt rheology or thermal characteristics, the powder materials need to be optimized with respect to size, shape, flowability and packing characteristics. In this contribution melt emulsification [1] and a precipitation process [2, 3] are discussed. Bulk polymer materials are directly converted to spherical micron sized particles in a single unit operation. The produced particles are characterized regarding size and morphology by electron and optical microscopy. The mechanism of liquid-liquid phase separation followed by precipitation are elucidated. Furthermore, structural characteristics of the obtained powders as well as flowability are analyzed and the product properties are correlated with process parameters. The potential of the aforementioned processes for the production of novel easy-to-handle PBF powders is demonstrated amongst others for polypropylene (PP), polycarbonate (PC) and L-polylactide (PLLA). References [1] Fanselow, S.; Emamjomeh, S. E.; Wirth, K.-E.; Schmidt, J.; Peukert, W., Chemical Engineering Science 141 (2016) 282–292. [2] Kloos, S.; Dechet, M. A.; Peukert, W.; Schmidt, J., Powder Technology 335 (2018) 275–284. [3] Dechet, M. A.; Demina, A.; Römling, L; Gómez Bonilla, J. S.; Lanyi, F. J.; Schubert, D. W.; Bück, A.; Peukert, W.; Schmidt, J., Additive Manufacturing 32 (2020) 100966.