Blow molding process

A method of forming a composite structure combining a textile substrate with a thermoplastic parison, the textile substrate having a front side surface, a back side surface and interstices, the method comprising:

• placing the textile substrate between at least two mold halves of an open mold,
• placing the thermoplastic parison between the mold halves of the open mold,
• introducing a first application of air pressure into the thermoplastic parison while the
• thermoplastic parison is in a heated molten condition, to thereby expand the thermoplastic parison against the back side surface and partially into the interstices of the textile substrate to form a combined thermoplastic parison and textile substrate,
• moving the mold halves to a partially closed position,
• allowing heat transfer between the combined thermoplastic parison and textile substrate while the mold halves are in the partially closed position thereby cooling the thermoplastic parison to increase the viscosity thereof and prevent complete penetration of the thermoplastic parison through the interstices of the textile substrate,
• moving the mold halves to fully close the mold around the combined thermoplastic parison and textile substrate, and
• introducing a second application of air pressure into the combined thermoplastic parison and textile substrate with the closed mold after allowing the heat transfer but while the parison is still heated and formable to further expand the parison and thereby conform the combined thermoplastic parison and textile substrate to the mold.