Aluminium foams have the most productive technology and versatile properties among the metal foams. At the Canadian Cymat company we developed Smart Metal HD aluminium foams which maximum density of 1.3 g/cm3 is in the aluminium matrix syntactic foam value range. This is the upper limit of the cellular aluminium where the material compression strength still remains constant up to even 40% strain. With this high density the aluminium foam compression strength increased to a level which was not achievable until know. Mechanical and microstructural studies of high density aluminium foams between 0.6 and 1.3 g/cm3 will be shown in which range the aluminium foam became castable without destroying the cellular structure.