In this study, a novel method two-step foaming method (TSFM) has been proposed to fabricate Al alloy foams with irregular shapes. The two steps Al alloy foaming process and cell-structures evolution have been investigated experimentally. The relationship between foamable precursor, foaming parameters and cell-structures of the final foam samples has been observed. Moreover, the Al foam samples with regular and irregular shapes prepared by TSFM are shown in this paper.