In order to study the effect of size, shape and bulk density, two types of WO3 powder samples with different bulk densities (low and high) were selected. These powder samples were subjected to reduction under similar condition. Tungsten metal powders obtained after reduction were subjected to SEM analysis to study the grain shape, size and its grain size distribution. Reduced powders were then characterized using Air permeability test and Laser particle granulometry test to find out average particle size and particle size distribution, respectively. SEM analysis and test results are detailed in this paper.