Abstract: A slurry mixture of alcohol, particles and a binding agent undergoes partial solidification and curve-shaped molding in sequence on flat and curved molding surfaces respectively, to produce a curve-shaped foam product suitable for further fabrication as components of curved structures. The flat molding surface is lined with a release cloth on which the slurry initially undergoes partial solidification and is then molded as flexible core material transferred to the curved molding surface for additional shape molding purposes while alcohol removal is completed by evaporation followed by resin filling infusion to form a composite core as the curve-shaped foam product.