Novel approaches for optimized powder processing of advanced ceramics are reviewed with an emphasis on direct-casting methods and solid freeform fabrication techniques. The fundamental principles for green body formation are discussed; a distinction is made between physical and chemical gels based on the nature of the induced gelation. An overview of the properties of dense suspensions is presented, with a focus on the factors controlling the maximum solids loading. Recent work on direct measurements of interparticle forces in ceramic systems is presented and related to rheological properties.