Abstract Direct powder rolling (DPR) can be used to create metallic sheet at a reduced cost compared to traditional methods. The process is particularly relevant for metals that are beneficiated to a powder form. The DPR process, however, is not yet optimised and the material properties corresponding to DPR sheet do not compare well with sheet produced from rolled metallic billet. This study explores the effect of DPR input parameters on DPR aluminium sheet material properties. Roll speed, roll gap, sintering time and sintering temperature are shown to have an impact on the density, microstructure, hardness and ductility of DPR aluminium strip. It is shown that a low roll speed and a small roll gap produced the most dense strip. A roll gap of 0.7 mm and roll speed of 0.366 rpm produced green strip with a density of 90% of cast aluminium while a roll gap of 0.8 mm and roll speed of 0.73 rpm produced green strip with a density of 79.6% of cast aluminium. In addition, a Vickers hardness analysis and a three-point bending test show that increasing the sintering temperature of the green DPR strip will produce softer aluminium strips with higher ductility, as expected.