Traditional primary explosives are usually heavy metal salts, especially salts of lead, such as lead azide (LA) and lead styphnate (LS), which can cause environmental pollution problems. The potassium salt of 4,6-dinitrobenzofuroxan (KDNBF) has attracted more and more attention due to its advantages of no heavy metal pollution to the environment and appropriate sensitivity. There are many reports on the thermal properties and applications of KDNBF, but few reports on the morphological properties. In addition, little is known about the optimal synthesis conditions of KDNBF with different morphologies in the preparation process. In this study, Taguchi's experimental design method was used to determine the optimal experimental conditions for obtaining the maximum yields of KDNBF with different morphologies. The synthesized KDNBF was identified by means of SEM, NMR, FTIR, EA, and TG-DSC, and its sensitivity was measured using BAM fallhammer, BAM friction tester, and electrostatic spark sensitivity tester. The experimental results indicated that the maximum yields of flaky and spherical KDNBFs could reach 85.6 % and 82.6 % after purification under the optimal experimental condition, respectively. The spherical KDNBF powder had a relatively denser structure than the flaky KDNBF powder. The thermal analyses showed that the activation energies of the decomposition reaction of the flaky and spherical KDNBF powders calculated by the Kissinger method were 171.5 and 188.5 kJ mol(-1), respectively, and the Ozawa method were 170.7 and 186.9 kJ mol(-1), respectively. The thermal stability of spherical KDNBF powder was higher than that of flaky KDNBF powder. In addition, the sensitivity tests showed that the spherical KDNBF powder was less sensitive than the flaky KDNBF powder.