Flawless porous fibrous alumina ceramics with high performance were fabricated via a novel approach involving direct coagulation casting and lost-mold method. Stable alumina suspensions were prepared by adding sodium tri-polyphosphate as dispersant using alumina fibers as raw material and K2SO4 as sintering aid. Resin-coated sand molds with designed shapes for suspension casting were fabricated through 3D printing with subsequent post-treatments. Alumina green bodies were obtained by in situ coagulation of the suspension after treating at 90 degrees C within 40 minutes. Porous alumina ceramics were obtained after direct furnace sintering of green bodies without demolding, in which the molds would collapse automatically at around 650 degrees C with less exhaust emission. The effect of various K2SO4 contents and sintering temperatures on mechanical properties of porous ceramics was investigated. The SEM results showed that the fibers interconnected with obvious interfacial bondings on junctions when sintered at 1450 degrees C. The XRD patterns showed that the sample sintered with various K2SO4 additions consisted of different phases, mainly including aluminosilicates. Porosity of ceramic samples increased slightly whereas the compressive strength enhanced significantly with increasing K2SO4 addition. The density of sintered samples with different K2SO4 contents was in accord with the porosity variation tendency. The ceramic samples had uniform pore size distribution with average size from 3.18 to 7.24 m as increasing K2SO4 addition to 40 wt%. This approach may provide a convenient and general route to fabricate various dense and porous advanced ceramics with complex shapes and good composition homogeneity.