The actual fabrication processes of targets for the transmutation of actinides in nuclear reactors will need to be dust-free and compatible with automation and remote operation. The developments reported here mark an important technical breakthrough in the fabrication of highly active materials. The sol-gel external gelation, modified by the addition of carbon, and infiltration methods have been used here to produce high-quality, dust-free yttria-stabilized zirconia beads, with excellent compaction and sintering properties. Furthermore, the beads produced in this way have higher porosity, which permits the infiltration of hitherto unattainable quantities of the actinide.