This paper characterizes the rarely mentioned but very damaging defects formed during the hot-cutting process of alumina green tape. Surface and edge morphologies of the hot-cutting surface and a natural surface were examined by optical microscope and scanning electron microscope before and after the sintering process. Obviously different from the natural surface, the hot-cutting surface had a transverse crack-like defect scattered over the surface and a tearing, notch-like defect on the lower edge. A 31 × 22 full factorial experiment was conducted to evaluate the flexural strength controlled by the hot-cutting defect and inherent defects in ceramics. Variance analysis revealed a significant interaction between surface and wearing. The wearing factor had a statistically significant impact on the fracture strength of the top surface but not that of the side and bottom surfaces.