Effects of patty thickness (0.95 and 1.27 cm), weight (90 and 113 g) and type of patty fill method (traditional gravity fill = FF and twisted through holes into mold = TF) were evaluated using low-fat (10%) ground beef. An increase in patty thickness from 0.95 cm to 1.27 cm, resulted in a decreased (P<0.01) sensory firmness and peak load (Newtons) and increased (P<0.01) initial juiciness. TF fill method and 1.27 cm thick FF treatments improved tenderness and juiciness over 0.95 cm thick FF patties. This study revealed that improvements in tenderness and juiciness of low-fat beef patties can be attained through use of appropriate patty formation procedures.