The ITTF’s mentions, in June 2007, on the VOC-free glue using rules, have been refined, in 1 Jan. 2009, up to higher standards due to the human health protection. Because of these reasons, the latest research focuses the processing of the table tennis rackets by materials and technologies that reduce or totally eliminate the using of glues.The processing of a sandwich composite plate based on Al alloy foam and rubber coating processed by injection moulding on the metallic foam provide the possibility to attach it to the wooden support of the tennis table racket by a mechanical route through the dovetail system. Thus, glues using is eliminated.The powder metallurgy (PM) technology has been used in order to process Al-based foams from Al alloys powder particles and NaCl granules. Powder particles of aluminum alloy of 200 μm average size, at 40% (wt.) content, are homogenized with NaCl granules for 3 mm and 4 mm, at 60% (wt.) content, followed by cold compaction at 500 MPa, sintering in argon atmosphere and ultrasonic washing. Thus, metallic foams are processed, having different properties depending on the NaCl granules sizes. For 3 mm NaCl granules, the metallic foams have the following characteristics: density (0.2…0.35) g/cm3, porosity (60…70) %, average diameter of the pores 2.15 mm. For 4 mm NaCl granules, the metallic foams have the following characteristics: density (0.15…0.25) g/cm3, porosity (65…75) %, average diameter of the pores 2.65 mm.The mixture of rubber and carbon black is deposited on the metallic foam surface by injection moulding process, developed at the injection pressure of 50 bar, temperature of (130…150)∘C. The injected rubber coating has the density of (0.9–1.4) g/cm3, the Shore hardness of (40…80) and (1 …4) mm thickness.The results of this research provide the following advantages: elimination of the glues as well as of the multiple gluing of the same rubber coating because of the injection moulding technique of the rubber on the foam; conservation of the tennis table racket weight because the metallic foam has a low density (0.15…0.35 g/cm3) and consequently a low mass (20…50 g) for a plate of 15 mm diameter and 1 mm thickness, including the dovetail system that allows the quick replacement of the covering.