A method to manufacture aluminium(Al) fiber using powder extrusion technology and its nonwoven fabric was investigated. The fiber diameter(d) was determined by Al powder diameter(D) and extrusion ratio(ER). A good correlation between theoretical equation, d=1.15D/$(ER)^{1/2}$ and experimental value was obtained. The sub-micron scale Al fiber was also made by repeated extrusion. Two different bonding techniques, i.e., sintering and inorganic additive bonding methods were empolyed. For the production of Al nonwoven fabric, the latter method has many advantages, including lower process temperature, process simplicity, and productivity. Unlike the general characteristics of nonwoven fabrics produced by conventional bonding processes, the mechanical property of Al nonwoven fabric was relatively low. To enhance the property, the modification of web carding and bonding system is necessary.