The effects of powder-blasting angle on the powder-blasting rate of a thick film prepared using a tape-casting technique were investigated. The results revealed that the etching rate was sensitive to the angle of powder blasting. The mechanism of this dependency was discussed based on brittle fracture and erosion caused by the powders blasted on the surface of the film. In addition, a new processing route for barrier ribs for plasma display panels was attempted, using the sensitive dependency of the etching characteristics on the powder-blasting angle. It was demonstrated that the ribs could be processed successfully using layers having different etching rates.