Abstract: The invention a method of forming complex shape of styrenic polymer foams in which a pressing surface is created, for example, by planing/machining a layer of an as formed extruded styrenic polymer plank, contacting said plank with a contoured die face and pressing the foam to form the complex shape.

Abstract: The invention is a process for the preparation of article comprising placing a film on each inner surface of each part of a two part mold; placing an article in the mold with film located between the surface of the mold and the article such that there is a small space between the article and the surface of the mold; closing the mold about the article; injecting between the film and the article an expandable plastic material under conditions that the article is coated with the expandable material and the expandable material does not expand; removing the plastic article with the expandable material coated thereon with the two films attached to the expandable plastic material. In another embodiment the invention is an article comprising a shaped plastic article; an expandable material coated in the shaped plastic article; and a film covering the material coated shaped plastic article.