Abstract: The invention relates to hard sided luggage shells and other containers manufactured using vacuum forming or pressure forming of thermoplastics. A process for making shells and containers with integrally molded frames is disclosed, and products made by the method. A method of manufacturing differential pressure formed containers with framed openings, but without the need to attach a separate frame element to the molded shell. A process also is disclosed for reducing the undesirable stretching of shell material that occurs during differential pressure forming, particularly the thinning of corner portions of the shell or container. The process of the invention more efficiently utilizes the thermoplastic material by moving material from otherwise offal portions into the molded product. An improved method for severing the offal material from the final product is disclosed.