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The purpose of this study was to attempt to establish a possible relationship between the physical characteristics of grain sorghum and its capacity to expand. Eleven national varieties of sorghum were studied and were characterized for color, weight of 100 grains, number of grains in 40 grams, grain density and texture. Before subjecting the samples to the popping process, the method was standardized with respect to the experimental load. These tests helped to select a 62-gram load. Likewise, the effect of grain moisture content was studied. Results indicated that a soaking time of 45 minutes gave the best percent expansion. Highly statistical significant differences were found in the physical characteristics among the eleven sorghum varieties, as was also the case with respect to change in volume, popped grains and percentage of popped grains, which varied between 7.42 to 89.29%. The initial volume of the grain was negatively associated to the percentage of expanded grains. The initial grain volume was significantly negatively related to the unpopped grain. The final volume significantly correlated with the number of grain in 40 grams, with endosperm texture and grain density. Even though physical structure is important in grain expansion, other factors like chemical composition may also be of significance.