Manufacturing metal parts by Metal Injection Moulding or Additive Manufacturing techniques is expanding rapidly. The shape and size of metal powders play an important role in determining process efficiency and properties of the final components. Spherical particles with optimum size distribution are typically favoured by MIM manufacturers since they improve the flow characteristics of the atomized powders and help achieve desired tolerances and properties in final components. It is important to characterize the morphology of atomized powders, to ensure they meet required size and shape specifications. This paper will describe automated image analysis, an ideal tool for characterising the size and shape distributions of atomized metal powders. Metal powders produced by different atomizing processes, having similar particle size distributions but different shape properties will be described. Such materials can be quantified in terms of surface roughness, circularity and elongation, which can be correlated with processing or end use performance.