A novel process was successfully developed to manufacture mullite-bonded porous SiC ceramics. In this technique, SiC particles were coated with a sintering additive (alumina) and pore former (high density polyethylene) in a two-step process composed of solgel and in situ polymerization techniques, respectively. After the formation of a green body, the porous samples were produced by pressureless sintering under air. The microstructures, phase components, and physical and mechanical properties of the developed porous ceramics were examined and compared with materials obtained by the traditional process. The results interpretation revealed that the flexural strength (35%) and porosity (8%), as well as the pore size of the samples fabricated by the novel process significantly increased as compared to regular ceramic parts. Further characterization indicated that the enhanced properties of the porous ceramics came from the good dispersion of the sintering additive and pore former into the SiC particles and from the higher mullite formation.