Method for compression molding cosmetic composite parts

A method for forming, via compression molding in a single molding operation, a fiber-composite part having at least one cosmetic surface, wherein the cosmetic surface is formed without post processing, the method comprising:

• forming an assemblage of feed constituents, wherein the assemblage includes:
• a. a plurality of fiber-bundle-based preforms, each preform comprising a plurality of fibers infused with a first resin, and
• b. a resin-only constituent consisting essentially of a second resin;
• and
• compression molding and thereby consolidating, in a mold cavity, the plurality of fiber-bundle-based preforms and the resin-only constituent, wherein the resin-only constituent is positioned in the assemblage so that the resin-only constituent abuts a surface of the mold cavity that forms the cosmetic surface of the fiber-composite part, and wherein consolidating comprises:
• a. a first consolidation, including:
• (i) increasing a temperature of the fiber-bundle-based preforms to reach melt-flow of the first resin, while maintaining a temperature of the resin-only constituent below a temperature required to achieve melt flow of the second resin;
• and
• (ii) increasing pressure in the mold cavity sufficient for greater than 50 percent consolidation of the fiber-bundle-based preforms but 25 percent or less consolidation of the resin-only constituent;
• and
• b. a second consolidation, including:
• (i) increasing a temperature of the resin-only constituent to reach melt-flow of the second resin;
• and
• (ii) increasing pressure in the mold cavity sufficient to complete consolidation of the resin-only constituent and the fiber-bundle-based preforms.