To achieve quality parts from a powder bed fusion process you need to ensure that the powder bed is consistent layer-to-layer, build-to-build. The best way to validate this is to check the particle size and particle shape of your powder feedstock, since these properties affect powder packing, flowability, response to heat, and surface finish. In this presentation we will show how laser diffraction using the Mastersizer 3000+ and automated image analysis using the Morphologi 4 can be used to accurately measure particle size and shape, and even predict process performance.