Sprayed multilayer polyurea and polyurethane composites

A method of producing a molded composite product, the method comprising the steps of:

• a) applying an aliphatic polyurea layer to a mold by spraying a first isocyanate material component and a first resin material component with a first spray system, the first spray system comprising a mechanical purge or liquid purge spray gun, the temperature of the first isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the first resin component ranging from 100° F. to 175° F. when being sprayed;
• b) applying a first elastomeric layer to the aliphatic polyurea layer by spraying a second isocyanate material component and a second resin material component with a second spray system, the second spray system comprising a secondary air purge spray gun, a secondary mechanical purge spray gun, or a secondary solvent purge spray gun the temperature of the second isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the second resin component ranging from 100° F. to 175° F. when being sprayed;
• c) applying a structural foam layer to the first elastomeric layer by spraying a third isocyanate material component and a third resin material component with a third spray system, the third spray system comprising a tertiary air purge spray gun, a tertiary mechanical purge spray gun, or a tertiary solvent purge spray gun, the temperature of the third isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the third resin component ranging from 100° F. to 175° F. when being sprayed;
• d) applying a second elastomeric layer to the structural foam layer by spraying a fourth isocyanate material component and a fourth resin material component with a fourth spray system, the fourth spray system comprising a quaternary air purge spray gun, a quaternary mechanical purge spray gun, or a quaternary solvent purge spray gun, the temperature of the fourth isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the fourth resin component ranging from 100° F. to 175° F. when being sprayed;
• e) allowing the layers to cure to form the molded composite product;
• and
• f) removing the molded composite product from the mold.