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Supercon has investigated an innovative process for the fabrication of Nb3Al conductor. Monofilament Nb-Al jelly-roll composite wire was fabricated. This wire was then converted to ultra-fine alloy powder by an electro-exploded wire technique, and the powder was used to make conductor by a powder-in-tube process. The development effort demonstrated that alloy powder particle sizes as small as 0.30 micrometers (median by volume) having a composition very near that of the input wire could be achieved using the electro-explosion process. Monofilament powder-in-tube wire was successfully fabricated without wire breakage. The results of the investigation will be discussed, with emphasis on powder characteristics. © 2004 American Institute of Physics [ABSTRACT FROM AUTHOR]