**Abstract**

This chapter involves the development of a new metal foam composite material using casting techniques. This work included the design and the development of a process to produce the metal foam and control it. The materials used to produce the foam consisted of aluminum. Using prefabricated hollow spheres assures a uniform pore size and cell wall thickness. Casting a metal into the interstitial space provides a solid medium to add a structural support to the foam. The experimental setup was designed and fabricated. By the use of the developed setup, aluminum metallic foam was developed from the raw aluminum. Some characteristics were studied to verify the findings with the published data.

**Keywords:** metallic foam, pores, honeycomb, foaming
