Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. In one embodiment, the thermoplastic material may be a composite material and the article is a deep-drawn article. In this embodiment, the method and system include a female die having an article-defining cavity defined by inner surfaces of the female die and an outer male die for forcing an inner portion of a blank of thermoplastic sandwich material having a cellular core and a predetermined amount of thermoplastic composite material placed on the blank into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn sandwich material. In a second embodiment in which the article formed is not deep-drawn, the outer male die is not required.

Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. An inner male die forces the thermoplastic composite material and the sandwich material within the peripheral edge portion together at a temperature and pressure sufficient to fuse the materials together to form a thermoplastic composite inner portion of the sandwich material.