The opportunities of the hot wall aerosol synthesis, i.e. conventional spray pyrolysis (CSP) method are demonstrated for the generation of highly spherical three-dimensional (3D) nanostructured phosphor particles with uniformly distributed components, phases and nano-clustered inner structure. With the presumption that certain particle morphology is formed during the evaporation/drying stage, the aerosol transport properties and powder generation are correlated with the particles structural and morphological features. With the help of various analyzing techniques like Field Emission Scanning Electron Microscopy (FE-SEM), Transmission Electron Microscopy (TEM) coupled with energy dispersive X-ray Analysis and STEM mode (TEM/EDS), X-ray Powder Diffraction (XRPD) and fluorescence measurements the feasible processing of up-conversion rare-earth Y2O3:Er, Yb phosphors powders are discussed. (C) 2013 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.