Abstract: Methods, systems, and apparatuses of manufacturing an automotive interior trim panel are provided. The method includes providing a mold having a negative side and a positive side, heating the mold using a first heater and a second heater, coupling the mold to a first powder box containing a first polymeric powder, molding a first polymer layer on the first side of the mold by rotating the mold, coupling the mold to a second powder box containing a second polymeric powder, and molding a second polymer layer on the first polymer layer by rotating the mold. The method further includes heating the second polymer layer during which the second polymer layer expands, compressing the thickness of the second polymer layer, cooling the positive side of the mold to reduce the temperature of the first polymer layer and the second polymer layer, and removing the part from the mold.

Abstract: An over-molded interior trim method and system are provided. In another aspect, a method of manufacturing a trim panel includes: injecting a liquid substrate polymer between molds to create a substrate, injecting a liquid urethane polymer into a cavity directly against the substrate to create a skin or cover, flowing or wrapping in a mold the urethane polymer around at least one peripheral edge of the substrate, and extending the urethane polymer onto a backside of the substrate.