Pulp bottle with molded interior lining and methods of making same

A method of fabricating a lined molded pulp container, the method comprising:

• generating a molded pulp shell, the shell comprising a top opening, a sidewall, and/or a bottom to the shell defining a cavity within the pulp shell;
• providing a polymer blank, the blank comprising a neck and an expandable portion;
• at least partially inserting the expandable portion of the blank into the shell via the top opening;
• and
• extending the expandable portion of the blank to make contact of an interior of the cavity of the pulp shell by,
• heating and softening at least the expandable portion of the blank,
• applying positive pressure to at least an interior of the expandable portion of the blank,
• concurrently applying vacuum around the pulp shell,
• wherein the extended expandable portion of the blank forms a lining of the interior of the cavity of the pulp shell,
• adhering the lining to the interior of the cavity of the pulp shell.