Abstract: Background Kelp is the economic algae with the highest production in China. However, most processed kelp products are still mainly in the form of initial processing products such as salted and dried kelp, which have relatively low economic value. Therefore, it is necessary to develop refined processed kelp products with higher economic added value to promote the upgrading and development of the kelp industry. Objective The study aims to develop a reconstituted kelp sandwich crisps snack food with crispy texture and good flavor. Methods This study reconstructed kelp and explored the effects of key processes such as forming and rebaking on the sensory quality, textural properties, and volatile flavor compounds of the product through single-factor and orthogonal experiments. Results The optimal parameters of forming process were: material-to-liquid ratio of 1∶3, grinding time of 5 min, and molding weight of 35 g. The optimal parameters of rebaking process is 130 ℃ for 5 minutes in an oven. Under this condition, the product achieved the best sensory and texture, with a relatively low content of aldehyde-type fishy substances (46.7 μg/kg). The content of floral ketones (32.65 μg/kg) and caramel-flavored furans and furfuryl alcohols (177.18 μg/kg) was higher, resulting in a better flavor. Significance This study not only increased the added value of kelp products but also provided theoretical basis and technical pathways for the high-value utilization of kelp resources, showing good prospects for industrialization.