When working with fabrication techniques that may use blended powders as feedstock, such as weld overlays or laser deposits, control of powder uniformity is important.  When using a single powder feeder, one of the challenging tasks is to control the percentage of two dissimilar metallic powders being processed.  This study optimizes parameters, such as powder flow rate and carrier gas, for different size and density of metallic powders. Two dissimilar materials, one being magnetic, were premixed for 25 min to obtain proper composition and distribution of the powders. After being dispensed by a powder feeder, the collected powder is then separated using an electromagnet and the mass of the powders are measured to determine the actual percentage of powders being dispensed. Design of experiments was used to develop a model for predicting the powder ratio over a range of operating conditions and for different powder characteristics.