Methods for making pluralities of air diffusers from a single blank

A method of forming a plurality of air diffusers from a single fiberglass blank, comprising:

• feeding said blank to a pre-forming station;
• pressing a first set of two air diffuser patterns into said blank at a middle portion of said blank;
• pressing a second set of two air diffuser patterns into said blank at a first two corners thereof;
• and
• pressing a third set of two air diffuser patterns into said blank at a second two corners thereof, wherein each said set of two air diffuser patterns is pressed at substantially the same time.

A method of forming a plurality of air diffusers, comprising:

• feeding a fiberglass and foil blank to a pre-forming station;
• substantially simultaneously, pressing an initial two air diffuser patterns into said blank;
• substantially simultaneously, pressing an intermediate two air diffuser patterns into said blank;
• substantially simultaneously, pressing a final two air diffuser patterns into said blank;
• feeding said blank to a molding station such that each of said two air diffuser patterns mate with a female air diffuser mold;
• pressing a male air diffuser mold into each said female air diffuser mold;
• heating said each female and male mold thereby yielding six air diffusers in said blank;
• feeding said blank to a trimming station;
• and
• cutting said blank.

A method of forming a plurality of air diffusers from a single blank, comprising:

• feeding a fiberglass and foil blank to a pre-forming station;
• substantially simultaneously, pressing an initial two air diffuser patterns into said blank in a middle portion thereof;
• substantially simultaneously, pressing an intermediate two air diffuser patterns into said blank in a first two corners thereof;
• substantially simultaneously, pressing a final two air diffuser patterns into said blank in a second two corners thereof;
• feeding said blank to a molding station such that each of said two air diffuser patterns mate with a female air diffuser mold;
• pressing a male air diffuser mold into each said female air diffuser mold;
• heating said each female and male mold thereby yielding six air diffusers in said blank;
• feeding said blank to a trimming station;
• and
• cutting perforation in said blank.