Method for obtaining high definition graphics in surfaces of molded plastic objects

A method of forming a high definition graphical design in a surface of a kayak body using plastic powders and a mold having an internal cavity, which comprises the steps:

• placing a reusable stencil having openings corresponding to the graphical design against a selected location on an inner surface of the cavity of a first portion of the mold;
• filling the openings in the stencil with a loose first cross-linked polyethylene plastic powder of a color for the graphical design;
• removing the stencil from the surface of the mold;
• covering the first plastic powder for the graphical design with a limited amount of a loose second cross-linked polyethylene plastic powder of a color for the kayak body and having a same plastic composition as the first cross-linked polyethylene plastic powder;
• adding to the first portion of the mold, over the limited amount of the second plastic powder, a quantity of the loose second plastic powder in an amount sufficient to form the kayak body;
• closing the mold by fastening a second mold portion to the first mold portion;
• placing the closed mold into an oven for heating of the mold;
• locally heating an exterior of the mold within the oven at a position of the first plastic powder and at a position of the limited amount of the second plastic powder to a temperature proximate a transition temperature of the first and second plastic powders to form a skin on at least the first plastic powder to retain the first plastic powder in a position as established by the openings in the stencil;
• continuing heating the mold in its entirety to at least the transition temperature of the first and second plastic powders for a time sufficient to convert the first and second plastic powders to a molten state;
• rotating the mold around a longitudinal axis of the mold during the continuing heating step in the oven until the first and second plastic powders have melted and molten plastic of the second plastic powder is distributed over the inner surface of the cavity of the mold to form the kayak body;
• cooling and rotating the heated mold to solidify the molten plastics;
• and
• removing the molded kayak body from the mold wherein the high definition graphical design is formed in the surface of the molded kayak body.