This paper investigates the effect of process variables such as zircon flour, filler material (Siliminate) and binder (bentonite) on viscosity of slurry in Vacuum Assisted Evaporative Pattern Casting (VAEPC) process. In order to evaluate the effect of selected process variables, the Response Surface Methodology (RSM) has been used to correlate the independent process variables with the desired coating characteristics by a mathematical model. The central composite rotatable design was used to conduct the experiments. The result indicates that viscosity of the slurry increase with increase in zircon flour, siliminate and bentonite. The scanning electronic microscope (SEM) was used to analyze the morphology of the powder mixture containing zircon flour and filler material. X-ray analysis of the samples was done within the diffraction angle interval of 20 to 85°. Differentially Thermal Analysis (DTA) was also carried to measure the temperature effect on the samples.