In present work, ultra-fine powders with alpha phase content higher than 95 wt% and specific surface area of 15.33 m2/g were prepared by mechanical activated combustion synthesis (MACS) process. The sinterability of as-fabricated Si3N4 as well as the microstructure and mechanical properties of the sintered bulk were investigated by comparing with a kind of commercial available Si3N4 powders used as diluents in MACS process. Employing hot-pressing method, both powders were sintered equally by using Y2O3 and Al2O3 as sintering aids. Results showed that smaller particle size and higher specific surface area were obtained by MACS process when compared with the commercial one. Bulk Si3N4 appeared approximately the same relative density, hardness, strength and fracture toughness, however, proved to be higher while using MACS powders.