A first aspect of the invention relates to the manufacture of disparate workpieces by the process of injection molding using a single base tool. The tool is made up of cavity and core halves, and each half is made up of separate, removable/interchangeable, inserts which, when combined in a particular order, form the workpiece-forming surface. All or any number of the inserts may be replaced with other inserts to alter the workpiece-forming surface and allow a large number of differently shaped workpieces (i.e. having different surface features and shapes) to be formed from a single base tool. In another aspect of the invention, the inserts are connected to respective thermally conductive cavity and core mounting plates, which are in turn connected to respective cavity and core heating/cooling plates so that insert-mounting holes need not be made in the heating/cooling plates.

A method of forming a bathtub includes forming a core from a core material, coupling the core to a bathtub shell, applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure, forming one or more openings in the bathtub shell, and substantially removing the core from between the bathtub shell and the reinforcement structure to define one or more fluid channels of the bathtub.

A molded pool step, a method of fabricating the pool step and a method of matching a decorative pattern on the pool step to the decorative pattern on a pool liner is disclosed. The pool step is fabricated by applying a decorative pattern to one surface of a transparent sheet of moldable material; positioning the sheet of material on a pool step mold such that the sheet contacts a molding surface of the pool step mold; molding the sheet of material on the pool step mold such that the decorative pattern is located a distance inwardly from an outer surface of the pool step and is thereby prevented being contacted by pool water or people using the pool. When the pool step is molded and installed the decorative pattern on the three-dimension pool step is substantially continuous with the decorative pattern on the liner adjacent the pool step.

A molded pool step, a method of fabricating the pool step and a method of matching a decorative pattern on the pool step to the decorative pattern on a pool liner is disclosed. The pool step is fabricated by applying a decorative pattern to one surface of a transparent sheet of moldable material; positioning the sheet of material on a pool step mold such that the sheet contacts a molding surface of the pool step mold; molding the sheet of material on the pool step mold such that the decorative pattern is located a distance inwardly from an outer surface of the pool step and is thereby prevented being contacted by pool water or people using the pool. When the pool step is molded and installed the decorative pattern on the three-dimension pool step is substantially continuous with the decorative pattern on the liner adjacent the pool step.

A method of manufacturing an article for a spa includes laminating a cosmetic film to a base substrate; laminating an acrylic film to the cosmetic film, the base substrate, cosmetic film and the acrylic film forming a layered assembly, and forming the layered assembly to shape.

A molded pool step, a method of fabricating the pool step and a method of matching a decorative pattern on the pool step to the decorative pattern on a pool liner is disclosed. The pool step is fabricated by applying a decorative pattern to one surface of a transparent sheet of moldable material; positioning the sheet of material on a pool step mold such that the sheet contacts a molding surface of the pool step mold; molding the sheet of material on the pool step mold such that the decorative pattern is located a distance inwardly from an outer surface of the pool step and is thereby prevented being contacted by pool water or people using the pool. When the pool step is molded and installed the decorative pattern on the three-dimension pool step is substantially continuous with the decorative pattern on the liner adjacent the pool step.

An expansion-molded article that can be firmly heat-fused with another member is provided. The expansion-molded article is one that may be heat-fused with another member, where the expansion-molded article includes at least one protrusion which is formed on at least one surface of the expansion-molded article including at least one surface is to be heat-fused with the another member. The at least one protrusion comprises at least two surfaces as viewed from above, and a boundary line between the at least two surfaces, where the at least one boundary line intersects a direction from an outside of the at least one protrusion toward a center of an apex of the at least one protrusion.

A method of forming a bathtub includes forming a core from a core material, coupling the core to a bathtub shell, applying a reinforcing material to the bathtub shell over the core to form a reinforcement structure, forming one or more openings in the bathtub shell, and substantially removing the core from between the bathtub shell and the reinforcement structure to define one or more fluid channels of the bathtub.

A method of manufacturing an article for a spa includes laminating a cosmetic film to a base substrate; laminating an acrylic film to the cosmetic film, the base substrate, cosmetic film and the acrylic film forming a layered assembly, and forming the layered assembly to shape.

A thermoset polymerizable casting compound, formulated for production of kitchen sinks and sanitary ware, including: (a) at least one monofunctional acrylic and/or methacrylic monomer from recycled material and/or of plant or animal origin, (b) at least one polyfunctional acrylic and/or methacrylic biomonomer of plant or animal origin, (c) at least one polymer or copolymer selected from (co)polyacrylates, (co)polymethacrylates, polyols, polyesters, rosins, polyterpene resins, each from recycled material or of plant or animal origin, where the substances according to (a)-(c) form a polymer binder, and (d) inorganic and/or organic filler particles of natural origin or from recycled material. The proportion of the monofunctional acrylic and/or methacrylic monomer(s) and of the polyfunctional acrylic and methacrylic biomonomer(s) is 10-40% by weight, the proportion of the polymer(s) or copolymer(s) is 1-16% by weight, the proportion of the inorganic and/or organic filler particles is 44-89% by weight, and the polymer binder further includes at least one polymerizable terpene or derivatives thereof.