Polymer powders are widely used in industry and are traditionally manufactured by processes using organic solvent or by grinding low molecular weight polymers with a post-polymerization step. This thesis aimss at the generation of polymer powders with a single-step continuous process, based on the use of supercritical CO2, hence without organic solvent. Before developing this process, the characterization of the mixture CO2/polymer was done. Solubility measurements were carried out and fitted with the Sanchez-Lacombe equation of state. Moreover, a capillary rheometry technique was implemented on-line, allowing the measurement of the viscosity of the polymer alone or in mixture with CO2, under process conditions. The modeling of swelling as a function of time led to the evaluation of the diffusion coefficient of CO2 into the polymer. Afterwards, two experimental devices were designed. A batch process with a pressurized autoclave was used to determine the influence of experimental parameters on powder production, with small amounts of material. Formation of small fibrous particles was obtained. In parallel, the continuous process was studied on an extruder adapted to CO2 introduction and equipped with mixing devices. This study, which led to foam manufacture, was used to evaluate efficiency and homogeneity of the mixing. Residence time distributions were determined by Raman spectroscopy on the die in order to evaluate the flowing in the extruder under different conditions. The equipment was also fitted with a specific nozzle allowing co-injection of hot air. Production of fibrous particles with two different size ranges was obtained.