Abstract:
A molding process for a variety of structures including sports boards is provided. The process includes steps of: creating a three dimensional CAD image of a product, routing the inside edge of the product in a product blank, routing the outside edge of the product in two cassette halves, routing the product blank, inserting closeout material into the routed areas, shaping the product blank, shaping the cassette halves, placing outer skin material for the product in one cassette half, placing inner skin material for the product in the second cassette half, inserting the shaped product blank in the cassette half, placing inner skin material over the shaped product blank, placing outer skin material over the inner skin material, placing the second cassette half over said outer skin material, thereby forming a cassette package, placing the cassette package between contoured molded jaws, shaping the cassette package, and curing the product.