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The fabrication of high-quality metallic powders has been attracted considerable attention in terms of producing advanced materials through additive manufacturing (AM) technology. The efficiency of AM products mainly dependent on the initial powder, therefore, characterisation of pre-alloyed powders become important. In this study, we explored the fabrication of Al0.5CoCrFeMnNi high-entropy alloy (HEA) powders by gas atomisation process and investigated their powder characteristics according to particle size distribution. X-ray diffraction results revealed the formation of major face-centred cubic and minor body-centred cubic phase by the addition of Al content. The detailed characterisations such as scanning electron microscopy, Auger electron spectroscopy and XPS analysis was carried out to examine the chemical composition of HEA powders. The relationship between secondary dendrite arm spacing and cooling rate was evaluated. The results demonstrated that produced alloy powders are spherical in shape with smooth surfaces, compositional homogeneity, indicating the gas-atomised powders are widely acceptable for additive manufacturing applications. [ABSTRACT FROM AUTHOR]