This paper shows results in the preparation of net-shape open-cell aluminum foams by a sintering-dissolution process (SDP). Al/NaCl compacts were prepared by cold uniaxial pressing of 70NaCl:30Al mixtures. Three different sizes of NaCl were employed, namely 600-850 m, 850-1410 m and 1410-3350 m. Compressibility tests showed that a maximum densification was reached when applying loads in the range 18-20 Ton; the green compacts were then sintered under argon at 670˚C. After sintering, when the aluminum forms a well-bonded networked, the imbedded NaCl particles are dissolved in water, leaving behind an open cell Al foam. In this way, Al foams with approximately 30 vol.% solids are obtained. The microstructure of the Al foams, as a function of NaCl particle size, was statistically characterized in terms of pore size (Feret Diameter), pore shape (Shape Factor), and pore density. Generally speaking, the pore size increased by increasing the size of the NaCl grains.