The use of glass microballoon (GMB) - epoxy syntactic foams as a sandwich core material is studied. The skins and foam core are fabricated and joined instantaneously unlike the procedures followed in the previous studies. Each successive layer of the sandwich is fabricated when the previous layer is in a semi-gelled state. These sandwich samples are characterized for their properties under flexural loading. The failure modes and mechanical properties are carefully investigated. The change in fabrication technique results in a significant increase in the load bearing pattern of the sandwich. In earlier studies, debonding was found to occur prematurely since the bonding between the skins and core is the weakest plane. Using the current technique, core cracking occurs first, followed by skin fiber breaking and debonding happens at the end. This ensures that the load carrying phase of the structure is extended considerably. The sandwich is also analytically studied using Reddy's higher order shear deformation theory. A higher order theory is selected as the sandwich can no longer be considered as a thin beam and thus shear effects also need to be considered in addition to bending effects. © Published under licence by IOP Publishing Ltd.