The invention provides an ultra-light prepreg with a sandwich structure and a preparation and forming process thereof, the ultra-light prepreg with the sandwich structure comprises a first
fiber reinforced layer, a thermal self-expansion layer and a second
fiber reinforced layer, the thermal self-expansion layer is located between the first
fiber reinforced layer and the second fiber reinforced layer, and the thermal self-expansion layer, the first fiber reinforced layer and the second fiber reinforced layer integrally form the sandwich structure in a mold. The method can be used for forming a thin-wall product with the thickness of 0.4 mm-2mm, and is different from a foaming mode of foaming shaping and prepreg sandwich forming of traditional shaped foams such as PVC (
polyvinyl chloride) and PMI (polymethacrylimide), so that not only can the forming problem of complex shapes or thin-wall special shapes be solved, but also the
delamination phenomenon caused by inconsistent resin systems of a sandwich structure
surface layer and a sandwich layer can be improved, and the product quality is improved. And the good performance of the product is ensured. The method can be directly
cut into a die for forming, so that the working procedures are reduced, and the production cost is reduced.