Open area core sandwich structure assembly with vehicle exterior surface glass

A process for forming a composite sandwich panel assembly, said process comprising:

• positioning a high gloss surface sheet formed of a sheet molding compound (SMC) comprising glass fiber reinforced thermosetting polyester, said high gloss surface sheet having a high gloss surface;
• joining a first face of an open area core to said high gloss surface sheet with a first moisture cure adhesive layer intermediate therebetween, said open are core having a plurality of walls that extend from the first face to a second face and define an ordered array of a plurality of pores wherein the plurality of pores are partially filled with the first moisture cure adhesive;
• embedding a first woven or non-woven cloth in said first moisture cure adhesive layer;
• joining a structural skin to the second face opposing the first face of said open area core with a second moisture cure adhesive layer intermediate therebetween, said structural skin formed of a glass fiber mat which is impregnated with the second moisture cure adhesive layer, said structural skin having a decorated layer provided on a surface thereof that is opposite said second moisture cure adhesive layer;
• embedding a second woven or non-woven cloth in said second moisture cure adhesive layer;
• and
• joining said high gloss surface sheet and said structural skin at their peripheries to form an edge defining a moisture resistant seal;
• wherein a plurality of pores near the moisture resistant seal are crushed such that said open area core is fully enclosed and moisture is inhibited from entering the interior of said composite sandwich panel assembly.