Abstract Porous materials are commonly found in nature and as industrial materials such as wood, carbon, foams, ceramics and bricks. In order to use them effectively, their mechanical properties must be understood in relation to their micro-structures. Foam made from non-flammable metal will remain non-flammable and the foam is generally recyclable back to its base material. This research work is mainly concentrated in producing porous aluminum castings using melt route Metallic foams typically retain some physical properties of their base material thus density and % Porosity is found. Porous castings were developed by melt route using soaked Precursors, steel net , aluminum net and by casting around granules technique.