The direct utilization of aluminium chips represents a resource-saving alternative to the conventional extrusion of cast ingots. Current research focuses on the direct processing of aluminium chips into sheet metal products. Chip-based sheets are realized by a new process chain consisting of hot extrusion of aluminium chips to a cylindrical open profile, flattening and subsequent rolling. For the extrusion of chip-based open profiles a porthole die is used. The extruded profiles are flattened and rolled to metal sheets. The properties of the hot extruded chip-based AA6060 sheets were examined by tensile tests and microstructural investigations. The results were compared with those obtained from material extruded from conventional cast billets. The chip-based specimens show mechanical properties which are comparable to conventionally produced aluminium sheets based on as-cast material. Further processing of the chip-based sheets by forming processes was analyzed by producing bent components and deep drawn cups. No significant differences between the bent components or deep-drawn cups made of chips and those from cast material are observed regarding their capability for further plastic forming operations. This makes the new process route a resource-efficient alternative for the production of aluminium sheet products, since aluminium chips are directly recycled without remelting and the energy-intensive casting is avoided. Moreover, the range of components and products produced directly from chips can be expanded, opening up new markets.