Method of thermoforming a plastic appliance door

A method of thermoforming an appliance door comprising:

• providing a male mold member shaped to the contour of an inner door liner to be formed;
• providing a female mold member shaped to the contour of an outer door panel to be formed;
• providing a movable shuttle box including a first plug assist, the shuttle box and first plug assist being moveable into registry with either of the male and female mold members;
• moving a first plastic sheet into position over the male mold member;
• placing the shuttle box and first plug assist into contact with the first plastic sheet and into registry with the male mold member while applying heat and vacuum to the first plastic sheet to draw the first plastic sheet against the male mold member to thereby form the inner door liner,
• withdrawing the shuttle box and first plug assist with the door liner attached thereto from the male mold member;
• moving the shuttle box and first plug assist with the door liner attached thereto into a vertically aligned position with respect to the female mold member;
• moving a second plastic sheet into position with respect to the female mold member;
• providing a second plug assist for cooperation with the female mold member;
• moving the female mold member into contact with one side of the second plastic sheet;
• actuating the second plug assist into contact with a side of the second plastic sheet that is opposite the side of the second plastic sheet in contact with the female mold member, into registry with the female mold member and applying heat and vacuum to the second plastic sheet to draw the second plastic sheet against the female mold member to thereby form the outer door panel;
• retracting the second plug assist from the outer door panel retained within the female mold member;
• moving the shuttle box and first plug assist with the inner door liner attached thereto into registry with the female mold member with the outer door panel retained therein and heat sealing the inner door liner and the outer door panel together along respective peripheral edges thereof to form the appliance door;
• and
• separating the shuttle box including the first plug assist and female mold member to allow for removal of the appliance door.