Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight

A method for producing a consolidated cellulosic article, comprising the steps of:

• providing a mat of cellulosic material and binder resin;
• providing a first contoured front platen having a first pattern;
• providing a first contoured rear platen having a pattern generally corresponding to the first pattern of the front platen;
• consolidating the mat between the first contoured front platen and the first contoured rear platen under heat and pressure to form a molded softboard having a contoured front surface and a correspondingly contoured rear surface, the softboard having a substantially uniform density and substantially uniform caliper;
• removing portions of the molded softboard up to a predetermined removal plane to form a softboard having a front surface and rear surface with desired contours;
• providing a second contoured front platen having a contour substantially corresponding to the contour of the front surface;
• providing a second contoured rear platen having a contour substantially corresponding to the contour of the rear surface;
• and
• consolidating the softboard between the second contoured front platen and the second contoured rear platen, under heat and pressure.