Process for manufacturing lightweight and durable window well

A method of manufacturing a window well, the method comprising:

• heating a fiber reinforced thermoplastic sheet to more than 250° F.;
• positioning, after heating, the fiber reinforced thermoplastic sheet within a mold having rib-forming features;
• and
• compressing the heated fiber reinforced thermoplastic sheet within the mold at a pressure of greater than 200 psi to form a body of the window well having a plurality of ribs,
• wherein at least one of the plurality of ribs formed by the mold has a height that varies along a length of the rib, the height being smaller at a central region of the body and greater at opposing end regions of the body.

A method of manufacturing a window well, the method comprising:

• providing a sheet of fiber reinforced thermoplastic comprising fibers having a length greater than 6 mm, wherein at least some of the fibers are oriented in multiple non-parallel directions relative to other fibers within the sheet;
• heating the sheet to a temperature greater than 250° F., such that the sheet increases in thickness by at least 10% relative to an initial thickness prior to heating;
• positioning the heated sheet within a mold having rib-forming features;
• and
• compressing the heated sheet within the mold at a pressure of greater than 200 psi to form a body of the window well having a plurality of ribs.