Abstract: The invention relates to a method of producing an article comprising a hollow three dimensional array of reinforcement elements encapsulated in a thermoplastic material, whereby a hollow parison of said thermoplastic material is located within said array of reinforcement elements, said reinforcement array being located in a mould spaced apart from the mould surface, and said parison being expanded into conformity with said mould surface to encapsulate said reinforcement by the production of a pressure drop across the wall of said parison.

Abstract: A method of forming a two-dimensional array of reinforcement elements completely encapsulated in a thermoplastic material. The reinforcement array is supported above a vacuum forming table on a plurality of pegs moveable upwards from the surface of the table, a sheet of hot thermoplastic material is positioned over the reinforcement array, and a vacuum is applied through the table to draw the thermoplastic material down and around underneath the reinforcement. The pegs are then retracted to a position substantially flush with the surface of the table once the thermoplastic material is capable of supporting the reinforcement, the vacuum then drawing the thermoplastic material around and underneath the reinforcement and to those parts of the reinforcement above the pegs. The thermoplastic material is then allowed to cool and set.