A method of manufacturing and supplying a net-moulded article of expandable syntactic material and a related shipping package are provided. The moulded article is formed at a manufacturing facility where the forming process can be controlled to ensure production of quality syntactic material articles. The moulded article is formed by dispensing the material into a mould having a cavity with a shape matching that of a desired syntactic article to be used in an assembly at a point of use. The mould and moulded article are covered with a protective film to form a mould kit which is shipped to the point of use location. At the point of use location the moulded article is removed from the mould and preferably immediately positioned in the assembly without significant cutting, trimming, forming or other labor intensive actions. Once positioned, the net-moulded article and the assembly are cured to integrate the moulded article with the assembly.
