Method for making a molded composite of a prepreg sheet and a molding material

A method for making a molded composite of a prepreg sheet and a molding material, comprising steps of:

• a) providing a mold assembly including
• a female mold including a female mold body having a first outer surface and a first inner surface which is opposite to the first outer surface and which has a mold cavity extending toward the first outer surface to terminate at a sheet-side region,
• a male mold including a male mold body having a second outer surface and a second inner surface which is opposite to the second outer surface and which has a pressing side region configured, in cooperation with the sheet side region to permit the prepreg sheet to be sandwiched therebetween, the pressing side region having at least one bore extending toward the second outer surface to terminate at a bore end and having a shape simulating that of the molding material, the second outer surface having at least one guiding channel extending to access to the bore end of the at least one bore, and
• at least one pressing unit including
• a plunger which has an engaging end and an actuated end opposite to each other and which is guided by the guiding channel to permit the engaging end to move toward the bore, and
• an actuating member configured to press the actuated end of the plunger;
• b) disposing the molding material in the at least one bore;
• c) interposing the prepreg sheet between the sheet side region of the female mold and the pressing side region of the male mold;
• d) combining the female mold with the male mold to permit the prepreg sheet to be sandwiched between the sheet side region of the female mold and the pressing side region of the male mold;
• and
• e) operating the actuating member to press the actuated end of the plunger so as to move the plunger toward the female mold, thereby permitting the engaged end of the plunger to press the molding material against the prepreg sheet.