Structural composite panel with metallic foam core

1. A method of forming a structural composite panel comprising:

machining a plurality of voids in a closed-cell foam core;

wherein the machined foam core includes a perimeter structure and a stiffening rib;

wherein the plurality of voids are defined between the perimeter structure and the stiffening rib;

positioning the closed-cell foam core between a first carbon-fiber panel and a second carbon-fiber panel, the closed-cell foam core being formed from a metallic material;

bonding each of the respective first carbon-fiber panel and second carbon-fiber panel to the closed-cell foam core, wherein the bonding includes:

heating each of the respective first and second carbon-fiber panels; and

applying pressure to each of the respective first and second carbon-fiber panels such that each of the respective first and second carbon-fiber panels are deformed into each of the plurality of machined voids.

2. The method of claim 1 , wherein positioning a closed-cell foam core between a first carbon-fiber panel and a second carbon-fiber panel is such that the perimeter structure of the foam core aligns with, and is interior to the perimeter of each of the first carbon-fiber panel and the second carbon-fiber panel.

3. The method of claim 1 , wherein each of the respective first and second carbon-fiber panels are pre-impregnated panels including a partially cured resin disposed about a fiber sheet; and

wherein heating each of the respective first and second carbon-fiber panels is operative to fully cure the partially cured resin.

4. The method of claim 1 , wherein the closed-cell foam core is aluminum.

5. The method of claim 1 , wherein the closed-cell foam core includes a porous cellular structure; and

wherein the average size of each pore of the porous cellular structure is between approximately 1 mm and approximately 8 mm.