Sandwich structures benefit from the geometrical stiffening effect due to their high cross-sectional area moment of inertia. Transferred to carbon fiber-reinforced plastic (CFRP) components, the needed amount of carbon fiber (CF) material can be reduced and with it the CO2 footprint. The combination of a light foam core with continuous fiber-reinforced face sheets is a suitable material combination for lightweight design. Traditionally, CFRP sandwich structures with a foam core are manufactured in a two-step process by combining a prefabricated foam core with fiber-reinforced face sheets. However, in addition to the reduction in the used CFRP material, manufacturing processes with a high efficiency are needed. The objective of this paper is the sandwich manufacturing and characterization by using the Direct Sandwich Composite Molding (D-SCM) process for the one-step production of CFRP sandwich structures. The D-SCM process utilizes the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF-reinforced face sheets. The results of this work show that the production of sandwich structures with the novel D-SCM process strategy is feasible in one single manufacturing step and achieves good impregnation qualities. The foam density and morphology significantly influence the core shear properties and thus the component behavior under a bending load
