Abstract: This study investigated the effects of different powder processing techniques on the physicochemical and structural characteristics of mango powder. Mango powder was treated using conventional grinding (CG), ball milling (BM) and vibratory crushing (VC) methods, yielding seven types of processed mango powder samples: conventional grinding (CG), ball milling samples with different grinding times (1, 2, 3 hours corresponding to BM1, BM2, BM3), and vibratory-crushed samples with different grinding times (1, 7, 15 minutes corresponding to VC1, VC7, VC15). By measuring physicochemical properties such as particle size, moisture content, water activity, and solubility, along with structural characteristics including differential scanning calorimetry and Fourier-transform infrared spectroscopy, the physicochemical and structural properties of mango powder were analyzed. Results showed that both BM and VC treatments significantly modified the physicochemical attributes of mango powder compared to the CG. BM and VC significantly reduced the particle size of the fruit powder. BM decreased the moisture content and water activity of mango powder, whereas VC exhibited an inverse pattern. BM and VC increased the water solubility of mango powder from 53.467%（CG） to 68.230% ( BM ) and 76.207% (VC), respectively. Based on physicochemical parameters, samples BM2 and VC7, which correspond to the optimal grinding times in the BM and VC groups respectively, were selected. Through the further determination of BM2 and VC7, it was found that the density, fluidity and solubility of BM2 and VC7 decreased, but effectively retarded the moisture absorption of mango powder and increased the water solubility and oil holding capacity. As the particle size of mango powder decreases, the peak temperature also decreases. BM2 treatment reduced the content of bound water and semi-bound water in the sample, while VC7 exhibited the opposite effect. No new chemical functional groups were detected in all mango powder, and all X-ray diffraction patterns showed similar profiles. However, BM2 and VC7 induced the formation of hemispherical or irregular structures in the mango powder. In summary, ball milling for 2 h and vibration crushing for 7 min can improve the quality of mango powder.