Method of molding large thin parts from reinforced plastic material

A method for molding large components, comprising the steps of:

• providing reinforced plastic pellets comprising at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material, the reinforcement particles comprising less than 15% of a total volume of the pellets and at least 40% of the reinforcement particles having a thickness of less than about 50 nanometers, said pellets having a modulus of elasticity greater than 6892 MPa, said reinforcement particles comprising 8-15% by volume of said total volume of said pellets, and at least 70% of said reinforcement particles having a thickness of 10 nanometers or less;
• melting the reinforced plastic pellets to produce plasticized material therefrom;
• communicating said plasticized material through a manifold to a cavity mold, said manifold having at least two spaced valve gates that are independently opened and closed as directed by a controller to selectively communicate said plasticized material through said manifold to said mold cavity at separate locations in the mold;
• applying a primary injection pressure to said plasticized material in said manifold to fill said mold cavity through sequential opening and closing of said valve gates as directed by said controller;
• applying a secondary injection pressure to said plasticized material in said manifold to continue to fill said mold cavity, said secondary injection pressure being less than said primary injection pressure;
• closing said valve gates to seal said manifold from said mold cavity when said mold cavity is filled;
• and
• holding said plasticized material within said manifold in compression while said mold cavity is open for removal of said molded component from said mold cavity, said compression being maintained with the assistance of said closed valve gates to prevent appreciable expansion of said material.