This research involves the investigation of process parameters for a new rapid machining process designed for metal foams. Metal foams are structures that contain a network of interconnected pores throughout the structure and surrounding surfaces. Traditional machining methods break down the pore walls of metal foams, creating a smeared surface finish with little to no surface porosity. The described research tasks include defining the significant process parameters for machining complex geometries of a metal foam, Trabecular Metal^TM, commonly used in medical applications. It was found that feed rate significantly reduces the effect of surface smear, especially at faster rates. Machining with harder infiltrant materials and in a cryogenic environment will also better maintain surface porosity during machining. The impact of this research will allow for the creation of complex porous parts with a variety of applications including custom artificial bone implants.