Method and apparatus for enhanced minimal shear molding utilizing extrusional, pelletization, and melt rheological control of pellets and micropellets and molded objects made therefrom

A method of minimal shear molding comprising:

• providing at least one of pellets, micropellets, and powders;
• and simultaneously forming at least one layer of a molded part with the at least one of pellets, micropellets, and powder;
• wherein the composition for each of the at least one layers comprises less than approximately 20% of the minor component when comprising more than one of the pellets, micropellets, and powders, and the size of the powder, if used, can be larger than the size of the pellet;
• wherein the pellets, micropellets, and powders used to form each of the at least one layers are compositionally different for each layer, such that each layer is compositionally different;
• wherein no layer consists of combinations of one size pellet and one size;
• and
• wherein no layer consists only of powder.

A rotationally molded article of at least one layer, formed from a chemical composition including at least one of pellets, micropellets, and powders;

• wherein the composition for each of the at least one layers comprises less than approximately 20% of the minor component when comprising more than one of the pellets, micropellets, and powders, and the size of the powder, if used, can be larger than the size of the pellet;
• wherein the pellets, micropellets, and powders used to form each of the at least one layers are compositionally different for each layer, such that each layer is compositionally different;
• wherein no layer consists only of combinations of one size pellet and one size micropellet;
• and
• wherein no layer consists only of powder.