Light weight component with internal reinforcement and method of making

A method of making a light weight component, comprising:

• forming a first metallic foam core into a desired configuration;
• applying a metallic shell to a portion of an exterior surface of the first metallic foam core after it has been formed into the desired configuration;
• arranging the first metallic foam core to be adjacent to a second metallic foam core such that the metallic shell applied to the portion of the exterior surface of the first metallic foam core is covered by the second metallic foam core and the first metallic foam core and the second metallic foam core define a desired pre-form shape;
• and
• applying an external metallic shell to an exterior surface of the desired pre-form shape, wherein the metallic shell applied to the portion of the exterior surface of the first metallic foam core provides structural reinforcement to the component.

A component, comprising:

• a pre-form shape defined by a plurality of metallic foam cores each having a desired configuration;
• a metallic shell applied to one of the plurality of metallic foam cores wherein the metallic shell is covered by another one of the plurality of metallic foam cores to define the pre-form shape;
• and
• an external metallic shell applied to an exterior surface of the pre-form shape.