Abstract: Controlled geometry pellets, which have at least one generally flat face having a cross-sectional shape with a rectangular envelope having an aspect ratio of at least 1.5, are provided. The controlled geometry pellets may include a plurality of reinforcing particulates dispersed throughout the thermoplastic resin. The reinforcing particulates typically have a largest dimension which is no more than about 90% of the largest pellet dimension. Compression molding methods of manufacturing a shaped article using the pellets are also provided. The methods include compression molding thermoplastic resin-based material to provide a molded article, where thermoplastic resin-based material comprises a plurality of the controlled geometry pellets.

Abstract: Compression molding methods of manufacturing a shaped article are provided. The methods include compression molding thermoplastic resin-based material to provide a molded article, where thermoplastic resin-based material comprises a plurality of controlled geometry pellets. The pellets include at least one generally flat face having a cross-sectional shape with a rectangular envelope having an aspect ratio of at least 1.5. The controlled geometry pellets may include a plurality of reinforcing particulates dispersed throughout the thermoplastic resin. The reinforcing particulates typically have a largest dimension which is no more than about 90% of the largest pellet dimension.