In this study, a cutting process using a milling machine for Al foam with and without remaining NaCl fabricated by a sintering and dissolution process was proposed. By comparing the surface pore structures of the Al foam after the cutting process, the possibility of cutting Al foam using a milling machine while retaining its pore structures was investigated. Although some flashes were observed around the pores, most of the pores remained at the cutting surface and retained their shape. Therefore, it was found that, Al foam can be cut using a milling machine without fracturing its pore structures at the surface by retaining the NaCl spacers. Namely, NaCl, which was used as spacers to generate pores in Al, can also have the role of strengthening Al foam during the cutting process. (C) 2017 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.