A polystyrene foam sheet comprising a polystyrene resin which contains 1 to 15 wt. % of a rubber component having a majority of particle sizes less than about 0.45 microns has been found to be superior for forming deep drawn articles. Optionally one or two films may be extrusion coated or laminated to the foam sheet prior to thermoforming. Also disclosed is a method for thermoforming the foam sheet. Preheat the sheet, clamp the sheet between the matched male (10) and female (50) mold members, move the members into final position while applying a vacuum through both members to both sides of the foamed sheet and then chill formed foam to set a final shape.
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