<p>In this study, aluminum foam sandwich panels (AFSs) were fabricated using the powder composite rolling method (PCRM), with aluminum powder and silicon powder as raw materials and TiH₂ as the foaming agent. The effects of foaming agent content and metal face sheet thickness on the uniformity of the pore structure and the metallurgical bonding quality of AFS were investigated. The bending performance and failure modes of AFS were investigated using quasi-static three-point bending tests combined with digital image correlation (DIC) technology. The results indicate that the foaming agent content has a more significant influence on the pore structure compared to the thickness of the metal face sheets. By comparing the energy absorption performance of samples with different foaming agent contents and face sheet thicknesses, it was found that the foaming agent content primarily influences the performance through the uniformity of the pore structure. Overall, the energy absorption levels of the samples followed the order: 0.8 wt.% foaming agent content &gt; 0.5 wt.% &gt; 1 wt.%. The face sheet thickness mainly affects the mechanical properties by altering the failure modes, and an increase in thickness contributes to improved bending performance. The 1 mm thick samples failed primarily by core shear and face sheet fracture, while the 2 mm thick samples exhibited core shear, core compaction, and face sheet yielding.</p>