Abstract: A method of forming a composite sandwich core molded article, including forming a thermo-elastic rigid foam core into a desired shape, wrapping the preformed foam core with a fabric, placing said wrapped preformed foam core in a mold whose inner confining surfaces form the shape of the final article, injecting a liquid thermosetting resin into the mold such that the thermosetting resin surrounds and wets the fabric wrapped about the preformed foam core, heating the mold to a temperature sufficient to expand the rigid foam core to compress the fabric wrapped surface of the foam core against the inner confining surfaces of the mold; and cooling the mold and removing the article from the mold.