During the various steps of aluminium production from liquid metal, a lot of scrap is generated due to machining operations. Therefore, recycling of aluminium scrap is an interesting subject because of the broad applications of this metal and low efficiency of processes used to recycle metal scrap. This paper introduces a new direct technique for recycling aluminium scrap with low energy consumption and cost without intervening metallurgical processes. Measured properties include green density, compressive strength, and hardness. Experimental results obtained show that the direct technique for recycled aluminium provides high productivity and about 80% green density (before sintering). In addition, the new technique provides very low air pollution emission and high metal saving as compared with conventional methods. (C) 2003 Elsevier Science B.V. All rights reserved.