a process is disclosed for forming a thermoplastic structure on the exterior surface of the heated mold form . a mold is heated to approximately two times the melting temperature of a thermoplastic material and particulate thermoplastic material then sprinkled onto the exterior surface of the heated mold . an adhesively bondable material may then be added to the semi - molten thermoplastic material structure . the mold is then cooled and the resulting thermoplastic structure removed . an apparatus for practicing the above process comprising a mold form , heating system , and particulate thermoplastic material dispensing system is also disclosed .