Abstract: Disclosed is a thermoforming mold that defines a surface of a thermoformed part, a cavity recess that defines part of the interior space of the thermoformed part, a bond flange ridge, a vent recess and a chamber recess in an offal region outside of the surface of the thermoformed part, where the chamber recess, the vent recess and the cavity recess collectively define a continuous recess and where the part does not extend substantially beyond the bond flange ridge. Also disclosed is a manufacturing method including molding a first and second plastic sheet to thermoforming molds, impressing the first and second plastic sheets together between the thermoforming molds to define the part, a seam, a vent and a chamber then inserting a blow needle into the chamber and using that blow needle to move a fluid through the interior space of the part through the vent and then removing the offal and the chamber from the part. Also disclosed is a thermoformed part manufactured using the mold and method described above.

Abstract: Disclosed is a panel section intended for assembly with other equivalent panel sections as a section door. The panel section includes two sheets thermoformed together to define a panel, an attachment tab, a living hinge unitarily formed between the panel and the attachment tab, a receiver portion configured to receive the attachment tab of an equivalent panel section when assembled as a sectional door, a first bearing surface and a second bearing surface, where the second bearing surface is configured to bear against the first bearing surface on the equivalent panel section when assembled as a sectional door. Also disclosed are a method of thermoforming the disclosed panel section and a method of assembling the disclosed sectional door.