Sheet molding compound with cores

A method for making a component of at least one thermoformable material, comprising the steps of:

• providing a first layer made of a first pre-impregnated material;
• providing a second layer made of a polymer material;
• providing a third layer made of said first pre-impregnated material;
• providing said first layer and said third layer to comprise several individually cut sheets of different sizes, said individually cut sheets used along different areas of said second layer for providing a different contour or thickness depending upon a predetermined desired shape of said component;
• providing an additional sheet that is in roll form and located at one end of said component, said additional sheet forming a connector for connection to a final assembly;
• placing said first layer, said second layer, and said third layer as an assembly into a mold such that said second layer is disposed between said first layer and said third layer to form a sheet;
• and
• curing said sheet in said mold by heating said mold to a desired cure temperature such that said first layer is bonded to said second layer, and said third layer is bonded to said second layer.