A solid state foaming process permits the use of up to 100% recycled pre-
and post-consumer polymer for the manufacture of foamed polymer material
and thermoformed foamed polymer articles. The process enables the
optional formation of integral unfoamed skins of controllable depth and
crystallinity on foamed polymeric materails suitable for a wide variety
of applications. Because this process does not alter the underlying
chemistry of the material all scrap from the manufacturing process may be
reused without additive to form new foamed polymeric materials and
articles.