This study discusses the production of Ti-6Al-4V titanium alloy powder using the Conduit Plasma Atomization (CPA) method for Additive Manufacturing (AM) applications. The primary focus of this study is the analysis of the size and shape of the powder particles produced, as well as the effect of process parameters on powder quality. The resulting powder has a particle size ranging from 0 to 500 μm, with the majority of the size distribution falling within the 50–300 μm range. The CPA method produces powder with a predominantly spherical morphology and smooth surface, which can improve powder flow and layer consistency in the AM process. This plasma atomization process utilizes electrical current parameters of 45A, a gas pressure of 2.5 bar, and a gas flow rate of 80 l/min, with a constant metal wire feed rate of 2 mm3/s. Although the resulting powder has an ideal size and shape for AM, oxygen contamination was found in the powder, which can affect the quality and mechanical properties of the material. Therefore, post-processing treatment is necessary to enhance microstructural homogeneity and reduce porosity, thereby increasing material durability. This study suggests optimizing process parameters and post-printing treatments to enhance the performance of Ti-6Al-4V powder for applications requiring high mechanical properties, such as engine components and medical implants. © Published under licence by IOP Publishing Ltd.