Abstract: A three dimensional structure, such as a watercraft, and a method for forming the three dimensional polymeric structure are described. The method includes providing at least one paint layer and a bonding layer coupled to the at least one paint layer and including a first exterior surface, extruding a structural sheet of at least one polymeric material at an extrusion temperature, wherein the sheet has a thickness of at least 0.25 inches and a second exterior surface, joining the first exterior surface to the second exterior surface to form a thermoformable sheet, forcing the thermoformable sheet against a three dimensional mold while the sheet is at a thermoformable temperature to deform the sheet into a three dimensional structure and removing the three dimensional structure from the mold.

Abstract: A method for forming a three dimensional polymeric structure includes providing at least one paint layer and providing a bonding layer coupled to the at least one paint layer to form an insert having a bonding surface provided by the bonding layer. A mold having a hollow interior bounded by an interior surface is further provided. The insert is positioned within the interior along a portion of the interior surface. At least one charge of thermoplastic material is deposited into the interior. The interior is heated while the mold is rotated and rocked. As a result, the thermoplastic material melts and is deposited against the interior surface of the mold and against the bonding surface of the insert to form a three dimensional structure within the interior. The three dimensional structure is then removed from the interior of the mold.