Production of pre-alloyed powder with top quality is critical for enabling additive manufacturing (AM) to reach its full potential. Improvements to close-coupled gas atomization (CC-GA) to suppress powder “satellite” attachments can contribute an important powder quality enhancement for a powder production method with potential for low-cost. Gas atomized powders with minimal satellite projections will have smoother spherical shape and are presumed to exhibit improved flowability and layer spreading characteristics, depending on the AM method. This flowing or spreading characteristic can be measured by funnel flow devices or powder rheometry. Both modeling approaches and experimental strategies have been developed in this study to address powder satellite suppression. These include simulation of time dependent atomizer spray chamber flow pattern development and the addition of supplemental gas flows and flow modification devices into the spray chamber. Recent progress on satellite mitigation for Ni-based alloy powders are reported.