Method of thermoforming a plastic refrigerator door

A method of thermoforming a refrigerator door comprising:

• providing first and second spaced and relatively movable female mold units, said second female mold unit being shaped complementary to a desired shape of an inner door liner to be formed;
• shuttling a first plastic sheet, a male mold member and a plug assist between said first and second female mold units with said first plastic sheet being positioned between said male mold member and said plug assist, said male mold member including at least one dike forming member;
• locating said male mold member against said first female mold unit;
• drawing said first female mold unit and said plug assist toward each other while applying heat and vacuum to said first plastic sheet such that said first plastic sheet forms an inner door liner, including at least one dike, on the male mold member;
• shuttling out said plug assist;
• positioning said inner door liner in the second female mold unit;
• shuttling out the male mold member from between said first and second female mold units;
• shuttling a second plastic sheet between said first and second female mold units;
• forming said second plastic sheet to said first female mold unit to make an outer refrigerator door panel;
• drawing said first and second female mold units together and heat sealing said inner door liner and said outer refrigerator door panel together along respective peripheral edges thereof to form a refrigerator door;
• separating said first and second female mold units;
• and
• removing the refrigerator door from between said first and second female mold units.