A three-dimensional, multi-layer plastic product that is resistant to damage caused by environmental factors such as heat, chemicals, desiccants,
oxygen, and / or weather is disclosed. The multi-layer product includes an
engineering resin layer affixed to a commodity resin layer. The
engineering resin layer of the multi-layer film may be directly fused to the commodity resin or post-
consumer regrind layer. Alternatively, the
engineering resin layer may be tied to the commodity resin or post-
consumer regrind layer through the use of one or more
adhesive and / or tie
layers. The commodity resin layer may be manufactured from an economical
polymer material such as a
polypropylene,
polyethylene,
polystyrene or post-
consumer regrind. Suitable engineering resins may be any of a variety of suitable materials such as a polysulphone,
polymethylpentene,
polyester,
polycarbonate,
polyetherimide, nylon, polyarylate, polyphenylenesulphide,
polyphenylene oxide, polyethersulphone, aromatic
polyketone,
liquid crystal polymer, and mixtures thereof, for example, a method for manufacturing a three-dimensional multi-layer plastic product is also disclosed which includes the steps of providing an extruded or laminated sheet comprising an engineering resin layer,
thermoforming a three-dimensional shell from the sheet, and injection molding a commodity resin layer onto the thermoformed shell.