TiO2 filled polytetrafluoroethylene (PTFE) composite were fabricated for microwave circuit applications. PTFE/TiO2 composites were prepared by cold pressing and hot treating. The particle size of TiO2 varied from 5 μm to 11 μm.TiO2 powders with different sizes were prepared by the solid state ceramic route. The effects of TiO2 particle size on the microstructure, density, moisture absorption, thermal conductivity and microwave dielectric properties of PTFE/TiO2 composites were investigated. The density showed an increasing trend as the TiO2 particle size increased, while the dielectric loss (tanδ) and moisture absorption decreased with the increase of TiO2 particle size. The dielectric constant (εr) and thermal conductivity (λ) decreased up to D50 = 6.5 μm and then sharply increased. Good properties with values of εr = 6.8, tanδ = 0.0012 and λ = 0.533 W?m?1?K?1 were obtained in PTFE/TiO2 composites when the particle size of TiO2 was 11 μm.