Abstract: An method of forming a thin walled section in an injection molded plastic part includes providing a mold having a first mold half, a second mold half, and a slide, wherein the first and second mold halves, and the slide define a mold cavity when assembled. The slide includes portions that define a thin walled section of the plastic part and is movable between a retracted position wherein the slide is partially retracted from the mold cavity and an engaged position wherein the slide is in position to define the final shape of the plastic part; injecting molten plastic into the mold cavity with the slide in the retracted position; moving the slide to the engaged position; allowing the molten plastic to cool; opening the mold halves and removing the plastic part.

Abstract: An interior panel for a motor vehicle provides a deployment door for an airbag assembly supported behind the panel. The deployment door has a peripheral end surface connected to the surrounding panel substrate, the connection being formed by a knit line. In this manner, a seamless deployment door for an airbag assembly is provided with a clean and consistent appearance, while at the same time quickly and easily breaking free from the surrounding panel.

Abstract: An airbag assembly for a motor vehicle does not require any heat stakes and permits a deployment door to be formed in the interior panel without the need for scoring or other pre-weakening thereof. The airbag chute is constructed of plastic and includes a substrate facing surface. A door assembly includes a metal door and a plastic door plate. The door plate is positioned between the substrate and the door portion, and has a substrate facing surface. The substrate facing surfaces of the airbag chute and the plastic door plate are attached to the substrate. The substrate facing surface of the plastic door plate engages the substrate over a contact area to distribute a force imposed on the plastic door plate from the deployment of the airbag.