Tetronics Limited has developed a process for producing ultra-fine (<150 nm) powder using atmospheric DC plasma technology. The procedure for producing aluminium nanopowder is briefly described with material characterisation results. The production method utilises the evaporation and subsequent gas phase condensation of an aluminium feed stock and offers the advantage of high throughput under controlled atmosphere conditions. This is complemented by controllable material passivation and dispersion at near atmospheric pressure. The work was funded under contract from QinetiQ (formally the United Kingdom Defence and Evaluation Research Agency) .