Abstract: According to the protection requirements and protection mechanism, a C/C-SiC ceramic/Al-based foam metal composite armour was designed. Under the premise that the surface density of the composite armor was ensured to be 44 kg/m², the residual bending strength after bullet's striking was used as the evaluation standard. The arranged position of the ceramic plate, the thickness of each bulletproof layer and the pore size in the foam metal were the research factors. The orthogonal simulation optimization scheme of three factors and three levels was designed. The numerical simulation of bullet penetration into the ceramic target plates and compression experiment of the composite armors with ballistic damage was carried out by using the finite element software ABAQUS. The residual bending strength of the designed composite armors was predicted and the structure was optimized. The ceramic composite armor samples were prepared according to the numerical simulation results, and the live shooting and bending experiments were carried out to verify their residual bending strength. The results show that the optimum structural form of the ceramic composite armor with the highest residual bending strength based on the MIL-A-46103E protection standard class III 2A is: The thickness of ceramic plate is 12 mm, the ceramic plate is laid out on the bulletproof surface, and the Al-based composite foam has a mixed pore size of 4 mm+10 mm. The order of primary and secondary factors affecting residual bending strength is: Ceramic plate thickness > ceramic plate location > Al-based composite foam pore size.