Abstract: A soft silicon rubber mould was made in advance with rapid prototyping technology.And then a kind of metal-skeleton roughcast with uniform inner pore was made by sintering the cast sample.Different materials and processes were studied for metal powder slurry non-pressing casting and sintering technique.The results show has 199# resin was an appropriate cohesive material and the double-component iron powder mixture of fine carbonyl iron grains and coarse iron grains could be casted and sintered with less shrink and more uniform inner structure than single fine carbonyl iron.