Features such as high strength to weight ratio; high energy, sound and vibration absorption and high heat transfer have caused the metallic foams to receive a considerable amount of attention from many researchers in recent years. The determining factor for the application of these materials is their structural properties that in this regard, porosity percent, size and shape of pores and complexity of the channels between the pores can be noted. Then the use of metallic foams in every application requires a method of fabrication to achievement a suitable structural properties. Therefore, in the present study, manufacturing method for the fabrication of highly porous copper foam (nearly 90 percent) and controlled pore size in order to use of them in catalysts and heat and mass transfer processes, was developed. The metallurgy powder process with sodium carbonate as a new space holder has been used to produce copper foams. At first to changing shape of copper powder, mechanical activation of them was performed for 4 hours at a rotating speed of 350 rpm. The ball-milled Cu powder was mixed with sodium carbonate powder with a volume fraction of 70, 80, 85 and 90% and then, powder mixture was uniaxially pressed in a steel mold at the pressure of 250 MPa. Afterward, the sintering and sodium carbonate removal of samples was performed. To determine the sintering temperature of copper and decomposition temperature of sodium carbonate, thermal analysis (DTA –TG) of copper and sodium carbonate powder was performed. Regarding the obtained results, sintering temperature and carbonate thermal decomposition temperature were respectively selected at 800 and 950 °C. The results of structural analysis of foams showed, the used fabrication method have a high ability to producing highly porous open-pore copper foams with controlled porosity percent and pore size. With regard to the tension analysis of cell walls, caused by the decomposition of sodium carbonate is the main reason of pores opening. The mechanical properties studying of samples showed with increasing of porosity percent, the flexural strength decreases linearly. The results of air permeability indicated good permeability of produced foams so that the permeability coefficient for all samples is in the range of 10 -10 m 2 . It also became clear that channels in the structure of foam sample have a great influence on the properties of the fluid permittivity so that by changing the entry and exit of the fluid in the samples, foam permeability parameters are changed much. The results of this study concluded that the fabricated copper foams have the special features allow using of them in heat and mass transfer processes. Keywords: Heat and mass transfer processes, Fuel cell, Copper foam, Powder metallurgy, Space holder.