Abstract: A method of manufacturing a mold tool for manufacturing poured foam parts wherein the mold tool includes lower and upper molds and the method includes 3D printing a composite mold to form a mold cavity for forming the poured foam parts. The 3D printing of lower and/or upper molds decreases the time and expense required for producing a mold tool whether for prototype or full production foam parts.

Abstract: A floor panel having a first and second layer. The first and second layer including polypropylene resin. The floor panel also including a foam layer located between the first and second layer. The first and second layer are bonded along an edge region to encapsulate the foam layer. In addition, the first layer defines a recess in a middle portion of the floor panel, wherein the recess includes a region where the first and second layer are bonded together.

Abstract: Embodiments of the present invention provide a forming tool for forming a substrate of the interior trim part, and methods for producing the interior trim part. The interior trim part includes a substrate, a layer of cover material, and an adhesive web disposed between the foam layer and the substrate. Further, methods are provided for forming the substrate of the interior trim part and vacuum forming the cover material over the substrate.