Abstract: A method for manufacturing a shaped panel from a continuous length of an expanded mat. The method includes transporting an expanded mat on a conveyor. The conveyor includes side chains and a plurality of spaced apart slats, which extend transversely between the side chains, on which the expanded mat is supported. The side chains and the plurality of slats define a plurality of openings in the conveyor. A length of the expanded mat is confined and shaped between a male mold and a female mold by moving the male mold and the female mold into mating relationship through one of the plurality of openings in the conveyor.

Abstract: A panel is formed from an expanded mat of fiberglass strands, a thermosetting resin binder is incorporated with these strands. When the panel is formed, it has a relief between the edges of the panel and the recessed portion of the panel. The panel is retained in its molded position by the setting of the thermosetting resin binder.

Abstract: A condensed mat of glass fibers incorporating a thermosetting resin is expanded over a mold. Gripping elements at the edges of the mold hold the edges of the expanded mat in place while a second mold confines and deforms the expanded mat between the two molds. Hot air is passed through the porous molds and through the expanded mat to set the thermosetting resin which thereby holds the expanded mat in its deformed shape to form a panel.