A new type of flake-processing mill is developed utilizing a novel configuration of high-speed orbiting ball media that rapidly converts 3D powders into quasi-2D flake powders in a quick and continuous manner. The novel device was designed and built and its milling characteristics were evaluated for differing powder sizes. As the powders are milled, their thicknesses decrease and their widths increase. The device is capable of continuously producing flakes as thin as 10 mu m from originally 150-mu m iron particles within seconds. However, the milling effectiveness decreases substantially for smaller powders. A hypothesis is proposed, which explains these milling trends on the basis of aerodynamics. Particles with lower inertial forces are observed to avoid the ball media as a result of local turbulence and subsequently forgo milling. (C) 2010 Elsevier B.V. All rights reserved.