Porous membrane structures are used in emulsification processes for the formulation of almost monodispersed emulsion droplets with focus on the melt emulsification of liquid metal melts. The melt is emulsified through nozzle plates and particulate sintered porous structures into a temperature controlled liquid where the liquid metal droplets solidify to form spherical shaped solid particles. Related to melt atomization techniques for powder production, the membrane emulsification processing route obtains an interesting alternative for the production of monodispersed spherical particles with low energy consumption.