Abstract: A method for forming a headliner including a fluted paper central substrate includes forming the fluted paper substrate in a first forming tool. The formed substrate is then moved to a second bonding tool. A cover layer and an adhesive layer are actuated in the bonding tool to secure the cover layer to the substrate. The bonding tool preferably consists of a heated upper portion adjacent the cover layer and the adhesive, and a cooled lower portion which receives the base material. The use of the cooled bottom portion maintains the dimensional accuracy of the base layer during the bonding process. The heated upper layer ensures efficient and quick actuation of the adhesive to bond the cover layer to the substrate.