A new route ("direct forming") was developed for forming dense PBI shapes from PBI powder. The new process affords the possibility of automated PBI powder shaping ("cold compaction") and densification in batches of multiple parts by a "powder-assisted hot isostatic pressing" process. Direct forming is a more productive alternative to hot compression molding. Two developments enable PBI direct forming : (1) the discovery that PBI powders that are porous and plasticized with moisture can be shaped by compaction at ambient temperatures (cold-compacted), and (2) a finding that cold-compacted shapes can be densified in large batches by a powder-assisted hot isostatic pressing. The porous PBI powder is formed from PBI in solution by a spray-precipitation process. When plasticized with moisture, this powder is cold-compactible to PBI shapes with densities up to 94% of that of ultimate density of PBI. These shapes, which have sufficient strength to be handled, are then further consolidated via powder-assisted hot isostatic pressing to shapes with excellent thermal and mechanical properties and densities of about 99% of the ultimate.