Zirconia powders with submicrometer particle size are consolidated using injection moulding technique. The green microstructure evolution and sintering behaviour of the moulded compacts after binder removal is characterized. Factors involving solid content, binder formulation, and debinding rate are considered to have a significant effect on the green microstructure of the mouldings and subsequent sintering behaviour, which have been verified under current investigation. Powder-binder suspensions with high solid content favours to develop homogeneous green compact microstructure with dense particle packing. This enables the sintering of the green compacts to be achieved at lower temperatures.