Abstract: A vehicle trim component is disclosed. A method for forming the trim component is also disclosed. The trim component is configured to support an airbag chute providing an airbag. The airbag is configured to be deployed through an opening. The trim component may comprise (a) a substrate a structure, (b) a cover comprising a skin made of a thermoplastic material (e.g. TPO having a substantially constant thickness of less than 0.7 mm) and a support layer coupled to the skin, and (c) a thermoplastic (e.g. foam) layer between the cover and the substrate. The thermoplastic foam) layer may be configured to attach the cover to the substrate. The airbag chute may be secured between the thermoplastic (e.g. foam) layer and the substrate. The support layer may be made of a foam material (e.g. polypropylene and/or polyethylene foam).

Abstract: An apparatus and method for making a trim panel. The method includes providing a preform laminate including a compressible material sandwiched between a flexible skin and a back skin. Positioning the preform laminate in the mold. Placing an insert with the preform laminate in the mold to created a step to establish a seam location and define a secondary area on the preform laminate. Compressing the compressible material by introducing a molten polymeric material to the mold forming a substrate and bonding the substrate to the preform laminate forming the trim component. The preform laminate folds onto itself and creates a crease along the step to simulate the seam and provide a contour change with the appearance of cushioning in the secondary area, and removing the trim panel component from the mold.

Abstract: An apparatus and method for making a trim panel. The method includes providing a preform laminate including a compressible material sandwiched between a flexible skin and a back skin. Positioning the preform laminate in the mold. Placing an insert with the preform laminate in the mold to created a step to establish a seam location and define a secondary area on the preform laminate. Compressing the compressible material by introducing a molten polymeric material to the mold forming a substrate and bonding the substrate to the preform laminate forming the trim component. The preform laminate folds onto itself and creates a crease along the step to simulate the seam and provide a contour change with the appearance of cushioning in the secondary area, and removing the trim panel component from the mold.