Rare earth Nd-Fe-B, a widely used magnet composition, was synthesized in a shape of powders using gas atomization, a rapid solidification based process. The microstructure and properties were investigated in accordance with solidification rate and densification. Detailed microstructural characterization was performed by using scanning electron microscope (SEM) and the structural properties were measured by using X-ray diffraction. Iron in the form of α-Fe phase was observed in powder of about 30 μm. It was expected that fraction of Nd2Fe14B phase increased rapidly with decrease in powder size, on the other hand that of α-Fe phase was decreased. Nd-rich phase diffused from grain boundary to particle boundary after hot deformation due to capillary action. The coercivity of the alloy decreased with increase in powder size. After hot deformation, Nd2Fe14B phase tend to align to c-axis.