A low temperature co-fired ceramics system consisting of a typical calcium aluminoborosilicate glass and alumina filler was used to investigate the effects of four different sizes, 13 nm, 0.5, 3, and 39 mu m, of a commercially available alumina filler on the resultant densification, crystallization, and dielectric properties. There was definitely a proper range of alumina particle size, which leads to desirable densification and enhanced dielectric properties. The onset temperatures of densification and crystallization depended strongly on the filler particle size. The 3 mu m sample as an optimum filler size exhibited a promising performance of k similar to 8.1 and Q similar to 160 at a resonant frequency of 14.8 GHz, which results from early densification and intensive crystallization of the anorthite CaAl2Si2O8 phase. Particularly, the use of nano-sized alumina (13 nm) retarded both densification by similar to 200 degrees C and crystallization by similar to 80 degrees C compared with the results of the 3 mu m alumina case. The dependence of the filler particle size was postulated as being related to the wetting and connectivity behavior of glass through consequent inter-reactions between glass and ceramic.