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Both open die and closed die powder compact forging can be used for the consolidation of Ti and pre-alloyed Ti 6Al 4V powders produced by a hydride-dehydride (HDH) process. The approach used is initial cold or warm compaction into cylindrical shapes, or into a specific pre-form shape appropriate for achieving a particular final forged shape. The economic benefit is near net-shape processing with minimum machining required after forging. Manufacturing costs are also minimised by forging a compact, with a sufficiently high enough density, in air, without a protective atmosphere. The challenge, from a manufacturing point of view, is the operation of a manufacturing route which gives rapid and qualified compaction to meet production demands and batch sintering to achieve a high enough density prior to final forging to shape. In addition to this the final product has to have the right level of mechanical properties. This paper reviews some key findings from powder compact production, through to sintering and forging. These will be presented in terms of alpha-beta phase distribution in the microstructure, the degree of porosity, heat treatment and their effects on mechanical properties.