Semiconducting barium titanate powderss with an average particle size less than 40 nm were used for tape casting. Green tapes with a thickness of 100-500 μm were tape-cast from aqueous slurry of barium titanate powders using polyvinyl alcohol (PVA) as binder and polyelectrolyte ammonium salt as dispersant. The solid loading, viscosity and rheological properties of the ceramic slurries were investigated. Slurries with low viscosity were obtained when the concentration of dispersant was 1.5-2.0 wt% (based on ceramic powders weight) with fixed 75 wt% solid loading. The highest solid loading and optimum dispersion were determined through the proper viscosity to cast. Microstructure and PTC effect of the ceramic chips were studied as a function of firing temperature. Yttrium ions were homogeneously diffused into barium lattices at a low temperature of 1240 °C, and fine-grained PTC ceramics with grain size of 1-2 μm were developed successfully. These results can be explained by the higher rate of reactivity of finer powders and stable behavior of the suspension.