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The research concerns the optimisation of sintering zirconium by spark plasma sintering (SPS) and modification of microstructures by introducing the manganese component. The problems of preparing mixtures for sintering were investigated. An additive of 2.5 wt% and 5 wt% manganese micropowders and 1 wt% and 2.5 wt% manganese nanopowders were utilized. An increase in the oxygen content in sintered mixtures made of zirconium and manganese along with an increase in their milling time in water was found. 100 rpm was determined as a safe mixing speed. The introduction of manganese nanopowders into zirconium did not significantly improved the homogeneity of the material. Manganese in larger quantities accumulates at the grain boundaries. The material is very difficult to machining, which is indicated by difficulties in sample preparation. • The conditions of high-speed mixing and sintering by the SPS method did not cause the entire manganese content to react to form ZrMn 2. • Due to the explosiveness of the mixture, 200 rpm was adopted as the optimal speed of homogenization of mixtures. • Mechanical milled Zr–Mn mixtures tend to oxidize. [ABSTRACT FROM AUTHOR]