Method for making a composite headliner

A method for making a unitary composite headliner adapted to be installed in a motor vehicle, the method comprising:

• providing at least one inner layer, two reinforcing layers, and a cover member, each of which comprises a recyclable polyester material, the at least one inner layer being configured to absorb sound and vibrations, and the reinforcing layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle;
• applying a polyester adhesive to the cover member;
• differentially heating the at least one inner layer and reinforcing layers in an oven configured to individually receive and heat each of the layers such that each of the reinforcing layers is heated to a respective predetermined reinforcing layer temperature, and the at least one inner layer is heated to a predetermined inner layer temperature less than either respective reinforcing layer temperature;
• inserting the layers and the cover member into a mold with the at least one inner layer being sandwiched between the reinforcing layers, and the cover member being adjacent one of the reinforcing layers;
• and
• compressing the layers and the cover member together to bond the layers and the cover member together and to form the headliner, wherein the headliner is recyclable as a unit.