Abstract: In one embodiment, a method for molding a molded-in-color panel in a mold includes providing a mold having a first mold member and a second mold member. One of the first mold member and the second mold member has an appearance portion forming surface and the other of the first mold member and the second mold member has a concealed portion forming surface corresponding with the appearance portion forming surface. The concealed portion forming surface forms a concealed portion of a panel and is free of any protuberances and ancillary structural members for facilitating ideal surface characteristics of an appearance portion of the panel. Molded-in-color resin is injected in the mold and cooled to form a molded-in-color panel. At least one ancillary structural member is welded to the concealed portion of the panel.

Abstract: A chilled air pressure box is provided for thermoforming a plastic sheet. The chilled air pressure box comprises a box, a box perimeter, an inlet valve, a compressed air source and a chilled air source. The box has an interior space within the box and defines an inlet opening. The box perimeter is for sealingly interfacing with a vacuum mold. The inlet valve is substantially disposed within the interior space, adjacent and aligned with the inlet opening such that when the inlet valve is closed the inlet opening is substantially sealed and when the inlet valve is opened the inlet opening is not sealed. The compressed air source is capable of pressurizing the interior space with compressed air and interfaces with the box. The chilled air source communicates with the inlet opening.

Abstract: In one embodiment, a method for molding a molded-in-color panel in a mold includes providing a mold having a first mold member and a second mold member. One of the first mold member and the second mold member has an appearance portion forming surface and the other of the first mold member and the second mold member has a concealed portion forming surface corresponding with the appearance portion forming surface. The concealed portion forming surface forms a concealed portion of a panel and is free of any protuberances and ancillary structural members for facilitating ideal surface characteristics of an appearance portion of the panel. Molded-in-color resin is injected in the mold and cooled to form a molded-in-color panel. At least one ancillary structural member is welded to the concealed portion of the panel.

Abstract: A chilled air pressure box is provided for thermoforming a plastic sheet. The chilled air pressure box comprises a box, a box perimeter, an inlet valve, a compressed air source and a chilled air source. The box has an interior space within the box and defines an inlet opening. The box perimeter is for sealingly interfacing with a vacuum mold. The inlet valve is substantially disposed within the interior space, adjacent and aligned with the inlet opening such that when the inlet valve is closed the inlet opening is substantially sealed and when the inlet valve is opened the inlet opening is not sealed. The compressed air source is capable of pressurizing the interior space with compressed air and interfaces with the box. The chilled air source communicates with the inlet opening.