Three dimensional printing is a unique technique that can print complex 3D structures that cannot be produced by other means, especially for rapid prototyping purpose. In this study, 3D mesh structures are created by three dimensional printing with four different TiNiHf powder sizes. Mesh structure green strength and surface smoothness are characterized in order to produce high quality 3D structures. Binder spreading time and spreading rate in the TiNiHf powders are measured in order to understand binder penetration difference in the mesh structures. The study shows that smaller TiNiHf particle size produces higher mesh structure green strength and surface smoothness, consistent with the observation that binder spreading is slower for smaller TiNiHf particles. (C) 2008 Elsevier B.V. All rights reserved.