Ti-43Al-5V-4Nb (at.%) intermetallic compounds with fully lamellar structure were fabricated by forging method without canning using the blended elemental powders. The process route consisted of powder blending, compacting, sintering and final fabrication by hot forging. During sintering, there existed expansion, which is detrimental to forging process. In order to overcome the difficulty, two-step forging was introduced. The total reduction of two-step forging was up to 65%. Nearly fully lamellar structure of TiAl alloy was obtained. Overall, an optimized and potentially lower cost processing route could be identified.