Abstract: The present disclosure relates generally to methods of analysing and manufacturing gypsum panels, for example, suitable for use as building surface products. The present disclosure relates more particularly to a method of forming a gypsum panel. The method includes forming a porous slurry layer on a receiving surface using a plurality of operating parameters, and allowing the porous slurry layer to set to form a gypsum core of a gypsum panel. The panel is then cut to form a cut surface that extends through the gypsum core, and an image of a region of the cut surface is captured. The image is analysed to identify bubbles intersecting the cut surface. A measure of bubble contact in the gypsum core is then calculated from the identified bubbles in the image. Based on the measure of bubble contact, an operating parameter used for forming the porous slurry layer is modified.