Within this paper, novel sandwich structures with top layers made of textile-reinforced plastics and polyurethane foam core are investigated with regard to their impact behavior. In contrast to conventional processing technologies, the expansion of the polyurethane foam is used to impregnate the textile reinforcement, creating sandwich top layers and core simultaneously. Given this single-step process, a high adaptability of the resulting mechanical properties can be achieved by varying the geometrical properties, such as foam core density, amount of textile layers and sandwich thickness. A design of experience approach is implemented by using statistical analysis of variance (ANOVA) to investigate the influence of these parameters. The experimental results, such as impact force and absorbed impact energy, gained from a drop weight testing setup, are analyzed and used to create statistical models. As a result, optimized sandwich structures according to stress-related requirements and geometrical constraints can be designed.