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The field activated sintering technique (FAST) is a powder consolidation process via the application of pulsed current and pressure. Compared with conventional hot pressing and hot isostatic pressing, FAST has demonstrated a rapid densification process that has the potential to minimize grain growth, which is crucial to achieving excellent physical properties. This work covers the physical phenomena, multi-scale analytical and numerical models, experimental studies, and application of FAST processing. Specifically, a coupled thermal-electric-densification framework for the design and optimization of FAST type processing has been proposed and implemented into a finite element package. A discrete finite element method is also developed to determine the effective thermal conductivity in a particulate system with realistic microstructure. Moreover, FAST simulation of a hip joint replacement is demonstrated.