Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet of material is provided with a variable resin concentration across its width, and the position of the variable resin concentration is correlated with the position of embossing features which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers to accommodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.