To compete with wrought steels for demanding applications such as gears in automotive engines, Powder Metallurgy, PM, materials must possess structural reliability. Density has been shown to be the dominant factor in determining fatigue resistance in PM structural components. PM routes which could overcome the 7.4 g/cm(3) barrier in ferrous components include: double press-double sinter, hot isostatic pressing (HIP), sinter- HIP, sinter + HIP, powder forging and (transient and supersolidus) liquid phase sintering. In order to provide high green densities, high pressure (IGPa) cold compaction, warm (similar to 140C) compaction and hydrocarbon-coated powders can be employed. Surface densification can be achieved by cold or warm work and includes cold work of hypoeutectoid alloys and ausforming. These processing routes are briefly reviewed, with particular attention to coated powders, warm compaction, high temperature sintering and the novel technique of carbothermic sintering in nitrogen of ferrous powders containing the easily oxidisable chromium and manganese.