Method for producing cured polymeric skins

A method of forming a cured polymeric skin, the method comprising:

• providing a sheet-form curable material including a thermosetting material, the thermosetting material including
• uncured phenolic resin,
• filler, and
• a catalyst in an amount of less than 1 wt. % relative to the content of the uncured phenolic resin,
• wherein the filler is present in a ratio of filler to uncured phenolic resin in an amount of 3:1 and greater, and further wherein the filler comprises a transition metal hydroxide and/or aluminium hydroxide in a ratio of metal hydroxide to uncured phenolic resin in an amount of 2:1 to 3:1;
• providing a substrate in particulate form;
• contacting the particulate substrate with a first surface of the sheet-form curable material;
• pressing the particulate substrate to the sheet-form curable material;
• and
• at least partially curing the sheet-form curable material to form a skin,
• wherein the configuration of the substrate is such that gas and/or vapour can be displaced from the pressing region, and a portion of the sheet-form curable material flows into the particulate substrate.