Microparticles with non-full structures are interesting in many applications. In their production, however, issues related to purification are common. To overcome these issues, in this study a continuous polymerization process was developed in order to obtain powdered, nano-structured microparticles using neither surfactants nor a liquid medium.More specifically, a photo-induced cationic polymerization in aerosol was applied. A monomer solution was sprayed and irradiated with UV-light. During the reactor passage, both polymerization and phase separation occurred inside the single droplet. By adjusting the solvents amounts and ratios, different structures could be realized. Nano-structured particles with tunable pore shapes and dimensions were obtained. Capsule-like structures were obtained with the addition of a co-solvent able to get involved in the polymerization.An active ingredient was encapsulated within the particles. Results showed that the addition of the active ingredient did not affect the synthesis; furthermore, the particles structure had an impact on the release kinetics.