Multi-stage gas atomization (hybrid gas and centrifugal) process was developed to prepare fine Sn3.0Ag0.5Cu solder powders. Initially, gas pressure and rotation speed, which were related to size distribution of atomized powders, were suspended as fixed parameters. Then, the nozzle-spindle distance was changed as a variable parameter (050 mm) to control the size of solder powders. After the melt stream acquired enough energy to form smaller sized droplets, strong impact and centrifugal force was applied using a conical spindle, to make the droplets even smaller. As a result, it was determined that achieving the optimum combination of potential energy and kinetic energy played an important role in lowering the powder size (D50) from 25 to 13 µm at the first collector, and then from 13 to 6 µm at the second collector.