The deposition of pure tin onto pure aluminum powder in its self-convective motion by magnetron DC sputtering was examined in order to prepare Al-Sn composite powder and thereby to improve the sintering of the aluminum particles, aiming at the development of highly structure-controlled porous aluminum materials. The fabrication of porous aluminum materials was carried out by space-holder method using the prepared Al-Sn composite powder in ordinary powder metallurgy processing. The effects of the sputterdeposition of tin on porous structure and mechanical properties of the sintered compact were investigated. It was found that the porous structure of the sintered porous materials with the porosity 80% was better regulated by the sputter-deposition, compared to that without the deposition. Regarding their compressive properties, it was found that the plateau stress of the sintered porous materials reached by the sputter-deposition twice as high as that without the deposition. Therefore it was concluded that coating of aluminum powder with tin deposits enables the porous-structure to be controlled more effectively in fabricating sintered highly porous aluminum materials, as well as improves their mechanical property.