Method for in-situ differential melting of polymers and parts formed therefrom

A method for molding, via compression molding, an article from two or more thermoplastic polymers, the article having a geometry characterized by a region wherein a first side of the article has a flat surface and an opposite side of the article has a protruding feature, the method comprising:

• forming a layup from which the article is molded, wherein a shape of the layup is substantially the same as the shape of article, and wherein the layup includes:
• a) a matrix precursor, wherein the matrix precursor is a first of the two or more thermoplastic polymer and has a first melt temperature, and
• b) an elastomer, wherein the elastomer is a second of the two or more thermoplastic polymers and has a second melt temperature, wherein the second melt temperature is lower than the first melt temperature, and
• wherein, in the layup, the elastomer is sited proximal to a location at which the protruding feature will be formed;
• sequentially melting the elastomer and the matrix precursor by subjecting the layup to heat and pressure in a mold;
• and
• reducing temperature below the first temperature, thereby solidifying the matrix precursor to a matrix and forming a region that contains the melted elastomer;
• reducing temperature to below the second temperature, thereby solidifying the elastomer within the region, resulting in a part having a region that substantially resists deformation.