A method for producing a spheroidized powder from a feed material, the method comprising: introducing a feed material comprising particles into a microwave plasma torch, wherein the introducing the feed material into the microwave plasma torch comprises injecting the feed material after a microwave plasma applicator for processing in the plume or exhaust of the microwave plasma torch and, wherein the collective average or median aspect ratio of the feed material is between 5:1 to 20:1; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder, wherein the spheroidized powder comprises a median sphericity of at least 0.91 and a particle size distribution of 15 μm to 105 μm; and wherein: i. the feed material comprises Yttrium Stabilized Zirconia and the particles are YSZ particles; ii. the feed material comprises Aluminum (Al) or Al alloy and the particles are Al particles or Al alloy particles; iii. the feed material comprises a water atomized alloy and the particles are water atomized alloy particles; iv. the feed material comprises Tantalum (Ta) and the particles are Ta particles; v. the feed material comprises Titanium Nitride (TiN) and the particles are TiN particles; vi. the feed material comprises Rhenium (Re) and the particles are Re particles; vii. the feed material comprises Tungsten and the particles are W particles; or viii. the feed material comprises Molybdenum (Mo) and the particles are Mo particles. introducing a feed material comprising particles into a microwave plasma torch, wherein the introducing the feed material into the microwave plasma torch comprises injecting the feed material after a microwave plasma applicator for processing in the plume or exhaust of the microwave plasma torch and, wherein the collective average or median aspect ratio of the feed material is between 5:1 to 20:1; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder, wherein the spheroidized powder comprises a median sphericity of at least 0.91 and a particle size distribution of 15 μm to 105 μm; and wherein: i. the feed material comprises Yttrium Stabilized Zirconia and the particles are YSZ particles; ii. the feed material comprises Aluminum (Al) or Al alloy and the particles are Al particles or Al alloy particles; iii. the feed material comprises a water atomized alloy and the particles are water atomized alloy particles; iv. the feed material comprises Tantalum (Ta) and the particles are Ta particles; v. the feed material comprises Titanium Nitride (TiN) and the particles are TiN particles; vi. the feed material comprises Rhenium (Re) and the particles are Re particles; vii. the feed material comprises Tungsten and the particles are W particles; or viii. the feed material comprises Molybdenum (Mo) and the particles are Mo particles. i. the feed material comprises Yttrium Stabilized Zirconia and the particles are YSZ particles; ii. the feed material comprises Aluminum (Al) or Al alloy and the particles are Al particles or Al alloy particles; iii. the feed material comprises a water atomized alloy and the particles are water atomized alloy particles; iv. the feed material comprises Tantalum (Ta) and the particles are Ta particles; v. the feed material comprises Titanium Nitride (TiN) and the particles are TiN particles; vi. the feed material comprises Rhenium (Re) and the particles are Re particles; vii. the feed material comprises Tungsten and the particles are W particles; or viii. the feed material comprises Molybdenum (Mo) and the particles are Mo particles.