The Low Density Core (LDC) process is a method for making metallic structures with solid surfaces covering a porous core. The development of the LDC process for making Ti-64 sheet based structures is described. Sheets similar to 2000 x 1200 x 4 mm(3) have been made with similar to 40 vol. % core porosity levels, and several forming techniques have been demonstrated. The LDC billet breakdown and forming behavior was found to be similar to conventional Ti-64 processes, so LDC Ti-64 sheet has the advantage that it can be fabricated into structures using well-established methods.