In this study a novel approach, termed the integrated mechanical and thermal activation (IMTA) process, was used to synthesize nanostructured WC-Co powder. As a result of the integration of mechanical and thermal activation, nanostructured WC-Co powder was synthesized below 1000degreesC, starting from WO3, CoO and graphite powder mixtures. Furthermore, consolidation of the nanostructured WC-Co powder via high velocity oxy-fuel (HVOF) thermal spraying and solid state sintering was investigated. The results demonstrated the feasibility of converting the nanostructured WC-Co powder to coatings and bulk components, the properties of which are either comparable to or better than that of the conventional coarse-grained counterparts. (C) Kluwer Academic Publishers.