Vacuum forming process

A vacuum forming process for molding a thermoset material, wherein the process comprises the following steps:

• (i) providing a mold for molding a sheet of a phenolic thermoset material, wherein the mold comprises an elastomeric material;
• (ii) placing the sheet of the phenolic thermoset material into contact with a surface of the mold;
• (iii) applying a vacuum to force the sheet of the phenolic thermoset material against the surface of the mold, and to at least partially cure the sheet of the phenolic thermoset material;
• and further wherein the phenolic thermoset material comprises:
• uncured phenolic resin;
• filler;
• and a catalyst in an amount of less than 2 wt. % relative to the content of phenolic resin, wherein the filler is present in a ratio of the filler to the uncured phenolic resin in an amount of 2.5:1 or greater, and further wherein the filler comprises a transition metal hydroxide and/or aluminum hydroxide in a ratio of the transition metal hydroxide and/or the aluminum hydroxide to the uncured phenolic resin in an amount of 1:1.5 to 3:1.