A major advantage of the powder metallurgical (P/M) manufacturing process is its ability to shape powder directly into a final component with a primary goal of a high quality, homogeneity of density and mechanical properties and productivity. In this research, powder die filling, powder transfer and powder compaction process have been studied in succession using a novel experimental set-up that utilizes a high strength transparent wall section to observe and record the particle movement and powder compaction during the entire sequence leading up to the formation of a green part. The natural powder pattern itself, as observed from the transparent wall section, is utilized for obtaining full-field displacement and strain measurement. The test set-up and the strain measurement technique offer a means of quickly obtaining density distribution data in select cases. In addition to the above, several powder flow characteristics during die filling, powder transfer and powder compaction under a range of test conditions have been noted through a series of high-speed photographic recordings. The observations reveal increased porosity in the die wall region due to friction and formation of shear bridges during powder transfer stages during suction filling. Spatial density data from optical strain measurements in the top, middle and bottom regions of the die are consistent with similar bulk density measurements from mass and volume of the 3 regions. (C) 2011 Elsevier B.A. All rights reserved.