Manufacturing metal parts by Metal Injection Molding (MIM) 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 favored 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 shows how automated image analysis is an ideal tool for characterizing the size and shape distributions of atomized metal powders.