Spacer containing dell free composite elements

A process for making a composite element constructed from i) a film (1) and ii) containing a polyurethane reinforcing layer, comprising the steps of: A) Inserting a sheet (1) into an open mold (4) / (5), B1) introducing polyurethane system components in the mold (4) / (5) to the inserted film (1), B2) introducing a spacer layer (3) in the mold (4 / (5) on the registered polyurethane system components, such that the outer edge of the spacer layer (3)) a distance from the edge of the resulting composite member B3) introducing polyurethane system components in the mold (4) / (5) (to the inserted spacer layer 3), and C) closing the mold (4) / (5) and reaction of the introduced polyurethane system components to form a polyurethane (ii), and D) if desired, separating supernatant film (1), wherein dimensions of the spacer layer (3) in the step (B2) are chosen so that the outer edge of the spacer layer (3) within the composite member has at least a distance of 10 mm to 300 mm from the edge of the resulting composite element.