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The present work has shown that hydrogen decrepitation of a 2:17-type Sm (Co0.673 Cu0.080Fe0.222Zr0.025)8.92 alloy is a very rapid and convenient means of producing powdered material for the production of polymer-bonded permanent magnets. The magnets made from the hydrogen decrepitated powder (average particle size ~100µm) exhibited improved demagnetization loop shapes, higher intrinsic coercivities and improved elevated temperature stability when compared with the magnets produced from the standard milled powder material (average particle size ~40µm). These differences in properties have been related to the differences in the character of the powders produced by the two methods of decrepitation.