Abstract: A process is disclosed for molding a foamed thermoplastic article characterized by a foamed core, a non-foamed exterior shell and a surface that reproducibly and faithfully replicates a predetermined portion of the inner surface of the mold in which the article is made, wherein a foamable mixture comprising molten thermoplastic material and blowing agent is introduced through a nozzle into a mold cavity defined by said inner surface of said mold and expands and is rigidified while in said mold cavity.