Abstract: A method of forming a panel having a surface pattern, comprising placing a superstate lamina shaped to define the desired pattern onto a substrate, the substrate and superstrate both comprising cellular thermoplastic materials which are mutually discernible, pressing a die face against the surface of the superstrate lamina and against at least that portion of the substrate adjacent the superstrate, said die face having a temperature above the softening temperature of both the superstate and substrate thermoplastic materials, to thereby collapse the cellular structure of the superstrate and the substrate where contacted by the die and form an integral non-cellular surface layer containing the pattern as an integral part thereof, cooling the die face to harden said layer, and removing the die.

Abstract: An article, such as a door, is made from a colored water-extended thermoplastic polymeric material, and is provided with a decorated pattern by fusion of a surface layer to form a non-cellular layer, the depth of fusion being different in different parts so that the depth of color is correspondingly different. The variation in color intensity provides a decorative pattern, and fusion of the cellular material is effected by pressing with a die in the shape of the desired pattern.