The present work utilized X-ray computed tomography (CT) and in situ laser dilatometry to correlate internal structural changes with dimensional variation during thermally driven binder removal. Nonuniform agglomerate arrangement and deformation introduced during compaction provide density gradients that drive binder migration. Simultaneously, density undergoes a slight decrease accompanied by a 1.0% loss in dimensional tolerance. This loss and CT difference images show that capillary forces generated during binder melting can change internal density distribution. This change in density has important implications for the binder removal process.