Simultaneous lamination and blow-molding process

A process for laminating a first element to a second element to form a single article having a predetermined shape including an interior cavity, the process comprising:

• placing a first sheet atop a first die;
• placing a first pressure introduction port atop the first sheet;
• placing a second sheet atop the first pressure introduction port and atop the first sheet;
• placing a second die atop the second sheet;
• clamping the first sheet, first pressure introduction port, and second sheet between the first and second dies to form an assembly comprising first die, first sheet, pressure introduction port, second sheet, and second die;
• introducing an applied gas pressure between the first and second sheets of the assembly, via the first pressure introduction port;
• heating the assembly to a temperature at which the first and second sheets can thermally deform, thereby achieving simultaneous lamination and blow molding of the first and second sheets;
• and
• cooling the assembly, such that the single article having the predetermined shape including the interior cavity is created.