Thermoplastic composite materials for portable information handling system enclosures

A method, comprising:

• heat pressing material layers to form a rectangularly shaped enclosure part for a portable information handling system, wherein the material layers include:
• a first fiber-reinforced thermoplastic outer layer including a first surface;
• a core thermoplastic layer comprising a plurality of thermoplastic film layers and a hexagonal pattern including cell walls forming hexagonal cells and multiple voids within each hexagonal cell separated by ribs each having a thickness of less than that of the cell walls;
• a second fiber-reinforced thermoplastic outer layer including a second surface;
• and
• a thermoplastic attachment feature bonded to the second fiber-reinforced thermoplastic outer layer at the second surface;
• wherein the thermoplastic attachment feature enables assembly of the enclosure part to the portable information handling system, and wherein the thermoplastic attachment feature includes a plurality of boss clusters, each boss cluster of the plurality of boss clusters provides a plurality of attachment points that are configured to attach the enclosure part to the portable information handling system and that protrude from the second surface of the second fiber-reinforced thermoplastic outer layer and a thermoplastic attachment layer covering the second surface of the second fiber-reinforced thermoplastic outer layer to enable attachment to the portable information handling system;
• wherein the thermoplastic attachment feature shares a common thermoplastic material with the second fiber-reinforced thermoplastic outer layer;
• and
• wherein a ratio of a maximum diagonal dimension to a minimum thickness of the enclosure part is between 170 and 400.