An exterior automotive quality paint coat is laminated to the surface of a
plastic car body member of panel. A dry paint transfer film is first
laminated to a relatively thin semi-rigid thermoformable resinous backing
sheet. The backing sheet side of the resulting laminate is then laminated
to a relatively thick thermoformable substrate sheet comprising the same
or a compatible polymeric material. The two sheets are joined by extruding
the thick substrate sheet and using the heat of extrusion to then laminate
the thin backing sheet to the thicker extruded substrate sheet. The
resulting thick sheet laminate is then thermoformed, preferably by first
heating the laminate to a forming temperature, followed by vacuum forming
the laminate to a three-dimensional shape of the finished automotive part,
such as a facia, ready to put on a vehicle.
