Titanium aluminide based alloys have shown significant potential in high temperature applications, but the high production cost of TiAl considerably limits its utilisation. Although the use of powder metallurgy processes can reduce the cost by minimising post-machining, an economical powder production route is still required. Therefore, in the present study a pre-alloyed Ti-48Al powder is developed using an elemental Ti and Al powder blend prepared using a simple vacuum heat treatment. A formation model of the intermetallic phases (i.e. TiAl, Ti3Al, TiAl2, TiAl3) during powder synthesis is proposed. In order to improve the sinterability, various milling methods (i.e. ball, attrition and shatterbox milling) are examined to reduce the particle size. The sintered microstructures, particularly the two-phased (alpha(2)-Ti3Al gamma-TiAl) lamellar structures are also investigated. Improved densification is achieved at 1300 degrees C, held for 2 h, using the manufactured powder, compared to the elemental powder blend (similar to 55%). With higher sintering temperatures or longer hold periods, increased density TiAl components are possible. (C) 2016 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.