Contoured structural element and production of the contoured structural element

A contoured structural element (100) for use as a core layer in a curved sandwich composite element, the contoured structural element (100) being formed from a PET-foam, the contoured structural element (100) being subdivided, except for a connecting layer (12), into a plurality of body elements (10), and the body elements (10) and the connecting layer (12) being aligned parallel to a base area (26) of the contoured structural element (100) which is in a planar state, at least one surface layer (16) of the connecting layer (12) and an adjoining surface layer (18) of the body elements (10) at least partly having a thermally densified layer (14);

• the body elements (10), the connecting layer (12) and the thermally densified layer (14) being made of the same material,
• wherein
• the at least one surface layer (16) of the connecting layer (12) and the adjoining surface layer (18) of the body elements (10) form the base area (26) of the contoured structural element (100) and wherein the thermally densified layer (14) fully extends over the base area (26) of the contoured structural element (100).