Abstract: A method of forming a part with a solid urethane elastomer skin is provided, wherein the mold is moved by a mold manipulation tool to present differently oriented surfaces of the mold in a horizontal orientation when the urethane elastomer is sprayed on each of the differently oriented surfaces. A multi-axis robot is provided with a spray head that sprays the urethane elastomer onto a mold surface. A mold manipulator moves the mold that has a plurality of differently oriented mold surfaces so that the surface to be sprayed is held in a horizontal orientation as they are coated with the urethane elastomer and for a predetermined time period after spray coating until the urethane elastomer sets up.

Abstract: A method of forming a part with a solid urethane elastomer skin is provided, wherein the mold is moved by a mold manipulation tool to present differently oriented surfaces of the mold in a horizontal orientation when the urethane elastomer is sprayed on each of the differently oriented surfaces. A multi-axis robot is provided with a spray head that sprays the urethane elastomer onto a mold surface. A mold manipulator moves the mold that has a plurality of differently oriented mold surfaces so that the surface to be sprayed is held in a horizontal orientation as they are coated with the urethane elastomer and for a predetermined time period after spray coating until the urethane elastomer sets up.

Abstract: A trim panel assembly for a door of a motor vehicle includes a trim panel substrate mounted on an inner panel of a door, a trim panel cover mounted on the trim panel substrate, and an arm rest portion formed by the trim panel substrate and trim panel cover extending longitudinally and inwardly into an occupant compartment of a motor vehicle and having an arm rest pad disposed between the trim panel cover and the trim panel substrate.

Abstract: A trim panel with a periphery edge wrap including a trim panel substrate having a periphery edge and a trim panel cover wrapped approximately one hundred eighty degrees about the periphery edge of the trim panel substrate.

Abstract: An apparatus for forming a trim panel with a one hundred eighty degree periphery edge wrap. The apparatus includes a molding tool having a mold cavity thereon. A loose form block is inserted in the cavity. The form block cooperates with the cavity to define the shape of the periphery edge. Further, the form block supports a trim cover panel such that it is wrapped approximately one hundred eighty degrees about the periphery edge of the trim panel substrate.