System and method for forming a ceramic sandwich-structured composite component

A method for forming a ceramic sandwich-structured composite component, the method comprising:

• applying one or more ceramic matrix composite (CMC) plies to at least a portion of at least one surface of a tool, the tool closable to define an interior cavity, the one or more CMC plies disposed within the interior cavity when the tool is closed;
• positioning a ceramic foam precursor with respect to the tool such that the ceramic foam precursor is disposed within the interior cavity when the tool is closed;
• closing the tool to seal the interior cavity;
• co-curing the ceramic foam precursor and the one or more CMC plies within the interior cavity, the ceramic foam precursor expanding within the interior cavity during the co-curing to form a ceramic core bonded to the one or more CMC plies, wherein the ceramic core and the one or more CMC plies form, after the co-curing, a green preform;
• removing the green preform from the tool;
• and
• sintering the green preform.

A system for forming a ceramic sandwich-structured composite component, the system comprising:

• a tool having one or more surfaces defining an interior cavity, the interior cavity configured to support a ceramic foam precursor and support one or more ceramic matrix composite (CMC) plies applied to the one or more surfaces, wherein the interior cavity is sealable;
• at least one thermal energy system actuatable by a controller to co-cure the ceramic foam precursor and the one or more CMC plies within the interior cavity to a green state to form a green preform, the ceramic foam precursor configured to expand within the interior cavity to apply a pressure to the one or more CMC plies to consolidate the one or more CMC plies;
• and
• a sintering unit configured to sinter the green preform.