A new integrated method for direct preparation of cermet materials is proposed consisting of a powder processing method allied to a special sintering step. The powder is obtained by mechanical alloying route where a specific morphologic design is searched to yield thin metal plated ceramic particles. These have the proper characteristics to engage the sintering by activated surface (SAS) consolidation method. The last is triggered by partial evaporation and reactive sintering of thin metal layers, therefore exposing high active surfaces with superior sinterability. Refractory sacrifice metal components are found to play an important role. The application of the integrated method to Ni-ZrO2 cermet with selected metal additives is investigated. Sintering temperatures can be reduced by more than 300°C for the same final density range. The resulted powders and pellets microstructures are analysed accordingly to the projected expected ones. The thermophysical and electrical properties measurements are performed for evaluate phases percolation.