Boehmite/multi-wall carbon nanotube (MWCNT) composite powders were prepared by hydrothermal processing. Starting chemical of aluminum acetate powders (2Al(OH)(C2H3O2)(2)) and MWCNTs were mixed for the formation of stoichiometric boehmite powders in an attempt to synthesize MWCNT-reinforced boehmite nano-powders via hydrothermal synthesis at 200 degrees C for 2 h. Kinetically stable suspensions of MWCNT boehmite composite powders were prepared and subsequently electrophoretic deposition (EPD) was applied to obtain complex shape products in the form of micro-gears. It is shown that the EPD technique is a powerful tool to manufacture small components in a short time. Detail TEM observations also indicated that hydrothermal processing provides an ideal environment to obtain homogeneous mixtures of MWCNT boehmite powders due to effective surface functionalization of MWCNTs under hydrothermal conditions. (C) 2010 Published by Elsevier Ltd and Techna Group S.r.l.