The powder-blasting characteristics of a thick film prepared using a tape-casting process have been investigated. The powder-blasting process is commonly used in the manufacturing of barrier ribs of plasma display panels. The effects of binder content and baking temperature on the powder-blasting rate of the thick film have been studied. The rates observed are discussed based on the volume fraction of the pores and the degradation of binder during the baking treatment. In addition, the effect of powder-blasting resistance of thick film on the morphology of barrier ribs formed is examined.