Abstract: A method of vacuum thermoforming a thermoplastic sheet together with a decorative insert. The decorative insert is placed on a first portion of a surface of a mold tool. The insert is retained in place by applying a localized vacuum to the insert via a plurality of passages through the first portion of the mold tool. The thermoplastic sheet can then be placed over the insert and over the remaining surface of the mold tool. The thermoplastic sheet is then drawn against the mold surface and over the decorative insert by applying a vacuum at a second portion of the surface. The mold surface can be grained or otherwise textured and this texture can extend continuously across the transition between the first and second portions. This permits use of the mold tool to apply a continuous textured surface when used to mold the thermoplastic sheet without the decorative insert.