The progresses obtained in the catalytic technology are driven by the social demands, such as environment, energy, chemicals, and fuels. The ultimate goal is to increase the process efficiency for scale-up. The molding catalysts are usually multicomponent material of millimetre-size consisting of the active phases, supports, and various molding additives suitable for commercial applications. Different from the powder catalysts, the molding catalysts should not only possess the catalytic activity of the powder catalyst but also consider the use of binder, lubricant, acid and pore-forming agent to satisfy the required mechanical strength and chemical stability to ensure that they can run smoothly and have a long life in industrial reactors. In addition, the shape and size of the molding catalysts affect the catalytic performance by affecting the flow state of the materials inside the reactor. Therefore, the molding process is complex and full of challenges. This review introduces the influence of molding conditions on both the mechanical and the catalytic properties at the fixed bed. Specifically, the effects of the types and amounts of additives, the addition sequence, the calcination conditions, the pulp ratio, and the shape and size of molding catalysts are focused. Weibull modulus can be used to measure the reliability of mechanical strength of brittle materials, and further judge and predict the reliability of catalyst strength value. In addition, this review also introduces the application of Weibull distribution in the reliability judgment and prediction of catalyst strength value, and the progress of computational fluid dynamics (CFD) simulation in assisting catalyst morphology design. The potential of Weibull distribution and CFD in future applications of molding catalyst are pointed out.