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In this research, the effect of the sintering and cooling process on geometry distortion and mechanical properties of PTFE/Al reactive material is investigated. Six particularly selected sintering temperatures, three different cooling modes (annealing cooling, normalizing cooling and rapid cooling), three different initial cooling temperatures, as well as six different final cooling temperatures were designed to compare the effects of sintering temperature, cooling rate, initial cooling temperature and final cooling temper-ature on the properties of reactive materials. Geometry distortion was quantitatively analyzed by a statistic on the dimensional changes of the specimens and microscopic morphology. A mechanical response properties transition from brittle to ductile was found and analyzed. By combining the ther-modynamic properties of PTFE and unsteady heat conduction theory, mechanisms of cooling induced morphology change, temperature induced distortion and strength decrease were obtained. The results showed that the cooling rate has the most significant effect on the morphology transformation, while initial cooling temperature has more significant effect on the dimensional distortion than final cooling temperature. As to the mechanical properties transition from brittle to plastic, a more prominent effect of initial cooling temperature than cooling rate and final temperature was revealed.