Gelcasting is a novel forming method for making high-quality ceramic parts by means of in situ polymerization where only a few percents of a polymerizable binder are needed. In this article the viscosities of lead zirconate titanate (PZT) suspensions with 15-52 vol.% solids loading were studied. After developing a concentrated PZT suspension with a low viscosity, gelcasting was successfully used to form PZT ceramic parts. Microstructures and piezoelectric properties of gelcast samples derived from suspensions with different solids loading were also investigated in comparison with those of die pressed ones. It was found that gelcast samples exhibited slightly stronger piezoelectric effect than the die pressed ones at the same sintering procedure. Based on the comparison of the density and pore structure results of the samples prepared by these two methods, their different piezoelectricity may be attributed to their microstructure difference. (C) 2003 Elsevier Science Ltd. All rights reserved.