The composition transitions between two neighbouring segregated bands in a rotating drum were studied using binary glass beads of 6 different size ratios. The concentration gradient of the coarser particles in the transition zone increased dramatically when the particle size ratio increased from 1.68 to 2.01 and then gradually decreased as the particle size ratio increased from 2.01 to 3.37. The concentration gradient profile could be explained by the differences of the dynamic angles of repose between the two components of the binary mixture. A novel, convenient and particulate-level composition controlled FGM processing method is proposed based on the transition zone structure between two neighbouring segregated bands. A Cu/Al(2)O(3)/Cu functionally graded material was successfully produced based on the proposed method using binary mixture of Cu and Al(2)O(3) powders. (C) 2011 Elsevier B.V. All rights reserved.