Patent ID: 8486317

Claim:
A method for forming a molded brassiere, comprising: positioning a multi-layer assembly of garment materials, comprising an outer layer, and inner layer, and an intermediate support layer, between a first heated mold element and a second heated mold element, the first heated mold element having a pair of spaced openings formed through a substantially planar inner surface, the second heated mold elements having a pair of female cavities formed therein a substantially planar inner surface and corresponding to the openings formed through the first heated mold element; moving said first and second heated mold elements in relation to one another to laminate said assembly of material into a substantially planar laminated assembly between the inner surfaces and to cut excess material from the laminated assembly to define a laminated brassiere assembly having a pair of spaced apart and interconnected breast cup areas, an integrally formed torso band portion extending outwardly from each breast cup area, and finished edges, without any additional sewing steps; and moving a third heated mold element having a pair of male molds through the pair of spaced openings in said first heated mold element into contact with said laminated assembly and into the pair of female cavities of the second heated mold element so that said third heated mold element forms a pair of breast cups in the breast cup areas of the laminated brassiere assembly, wherein the third heated mold element is engaged to move through the pair of spaced openings of the first heated mold element simultaneously to moving the first and second heated mold elements in relation to one another.