A method of preparing a cBN composite powder in a multi-step milling process with controlled milling debris production, the method comprising: forming a first powder mixture by adding one or more binder component materials and a first cBN component to milling equipment, the binder component materials having a D50 particle size value of 3.0 to 4.0 microns and a size distribution where the D10 value is 1.0 micron and the D90 value is 10 microns; wherein the binder component materials comprise powders having a composition that is selected from the group consisting of oxides, nitrides, and carbides of Group IV, V and VI elements of the periodic table and combinations thereof and optionally further comprising a composition that is selected from the group consisting of TiN, TiC, Ti(C,N), ZrN, Co, Al, and mixtures thereof; milling the first powder mixture for a first milling time of 1 hour to 24 hours to reduce the D50 particle size of the binder component materials within the first powder mixture at least 50%; combining a second cBN component with the milled first powder mixture to form a second powder mixture; and milling the second powder mixture for a second milling time of 15 minutes to 7 hours to form the cBN composite powder, the second milling time being less than the first milling time; wherein a ratio of the D50 value of the second cBN component to the D50 value of the first cBN component is at least 3; and wherein cBN is present in the milled second powder mixture in an amount between 5 and 70 wt %; wherein the D50 value of the first cBN component is between 0.2 micron and 2.0 microns and the D50 value of the second cBN component is between 1.2 micron and 6.0 microns. forming a first powder mixture by adding one or more binder component materials and a first cBN component to milling equipment, the binder component materials having a D50 particle size value of 3.0 to 4.0 microns and a size distribution where the D10 value is 1.0 micron and the D90 value is 10 microns; wherein the binder component materials comprise powders having a composition that is selected from the group consisting of oxides, nitrides, and carbides of Group IV, V and VI elements of the periodic table and combinations thereof and optionally further comprising a composition that is selected from the group consisting of TiN, TiC, Ti(C,N), ZrN, Co, Al, and mixtures thereof; milling the first powder mixture for a first milling time of 1 hour to 24 hours to reduce the D50 particle size of the binder component materials within the first powder mixture at least 50%; combining a second cBN component with the milled first powder mixture to form a second powder mixture; and milling the second powder mixture for a second milling time of 15 minutes to 7 hours to form the cBN composite powder, the second milling time being less than the first milling time; wherein a ratio of the D50 value of the second cBN component to the D50 value of the first cBN component is at least 3; and wherein cBN is present in the milled second powder mixture in an amount between 5 and 70 wt %; wherein the D50 value of the first cBN component is between 0.2 micron and 2.0 microns and the D50 value of the second cBN component is between 1.2 micron and 6.0 microns.