Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl to form a piercing therethrough; b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer; d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer; e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer; f) advancing the interior component to another position, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: A method of illuminating a component, having an outer skin layer, the method including the steps of: forming the outer surface layer from at least two separate pieces of an outer skin layer, the outer skin layer having a show surface and an opposite backing surface; forming a seam in the outer surface layer such that the at least two separate pieces are secured to each other; locating an elongated light conducting medium in the seam and behind a stitch securing the at least two separate pieces together; and securing the elongated light conducting medium to the outer surface layer.

Abstract: An integrated structural system for a vehicle, the system having: a structural member; a means for securing a first beam component to the structural member, the first beam component being molded from a first amount of thermoplastic material; and a means for securing a second beam component to the first beam component, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component.

Abstract: A method for stitching an interior component is provided. The method including the steps of: stitching an outer skin layer of the interior component with a single needle chain stitch machine having a rotary looper; descending a needle of the machine through the interior component; retracting the needle after is has descended through the interior component; engaging a thread loop formed during the retraction of the needle after it has descended through the interior component with a hook of the rotary looper, wherein a portion of interior component is located above and below the rotary looper as it rotates; and moving the interior component relative to the needle and rotary looper in order to establish a stitch length.

Abstract: A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of a robotic sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the robotic sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: An apparatus for stitching a component is provided. The apparatus includes an awl bar assembly coupled to a first drive device. The awl bar assembly is moved from a first position to a second position along the stitch path with an external drive device. A second drive device is coupled to the first drive device. A needle bar assembly is provided having a needle. The needle moves between an inserted and a withdrawn position, the needle bar assembly being pivotally coupled to the second drive device, the needle bar assembly moves from the first position to the second position with the same external drive device driving the awl bar assembly. A biasing member is coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in the second position in response to the needle bar being moved to the withdrawn position.

Abstract: An apparatus for stitching an interior component is disclosed herein. The component having an outer skin layer and the apparatus is a single needle chain stitch machine with a rotary looper and wherein a needle of the apparatus descends through the interior component and a hook of the rotary looper engages a thread loop formed during retraction of the needle after it has descended through the interior component; and wherein the apparatus further includes a mechanism for moving the interior component relative to the needle and looper to establish a stitch length.

Abstract: A method of applying stitching to an interior component is provided herein.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl to form a piercing therethrough; b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer; d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer; e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer; f) advancing the interior component to another position, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating an outer skin layer, a substrate layer and an intermediary layer of the interior component with an awl to form a piercing therethrough; b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer; d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer; e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer; f) advancing the interior component to another position; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: An integrated structural system for a vehicle, the system having: a structural member; a means for securing a first beam component to the structural member, the first beam component being molded from a first amount of thermoplastic material; and a means for securing a second beam component to the first beam component, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component.

Abstract: A method of illuminating a component, having an outer skin layer, the method including the steps of: forming a seam of the outer skin layer; and locating an elongated light conducting medium in the seam.

Abstract: An apparatus for stitching an interior component is disclosed herein. The component having an outer skin layer and the apparatus is a single needle chain stitch machine with a rotary looper and wherein a needle of the apparatus descends through the interior component and a hook of the rotary looper engages a thread loop formed during retraction of the needle after it has descended through the interior component; and wherein the apparatus further includes a mechanism for moving the interior component relative to the needle and looper to establish a stitch length.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating an outer skin layer, a substrate layer and an intermediary layer of the interior component with an awl to form a piercing therethrough; b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer; d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer; e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer; f) advancing the interior component to another position; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: An integrated structural system for a vehicle is provided, the integrated structural system having: a structural member; a first beam component secured to the structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material, wherein the configuration of the first beam component is defined by the molding process; and a second beam component secured directly and only to the first beam component by a vibration weld, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component.

Abstract: A method of forming an item with electromagnetic interference shielding, the method including the steps of: inserting a first polymer into a first compounding extruder, wherein the first compounding extruder provides a first melted charge; inserting the first melted charge into a second compounding extruder, wherein the second compounding extruder introduces a plurality of conductive fibers into the first melted charge and wherein the second compounding extruder provides a second melted charge comprising the first melted charge and a plurality of conductive fibers; depositing the second melted charge onto a least one die of a compression mold; and closing the compression mold about the second melted charge in order to form the item.

Abstract: A method for forming an integrated structural system for a vehicle is provided. The method including the steps of: securing a first beam component to a structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material, the structural member being formed from a material different than the first amount of thermoplastic material; and securing a second beam component to the first beam component, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component.

Abstract: A method for forming an integrated structural system for a vehicle is provided. The method including the steps of: securing a first beam component to a structural member by a molding process, the first beam component being molded from a first amount of thermoplastic material, the structural member being formed from a material different than the first amount of thermoplastic material; and securing a second beam component to the first beam component, the second beam component being separately molded from a second amount of thermoplastic material, the second beam component having a configuration different from the first beam component.

Abstract: A method of making a reinforced component by depositing a polymer into an extrusion deposition unit, during the plastication process a reinforcing material is deposited into the extrusion deposition unit. The amount and type of fiber is varied in order to provide a molded component with varying degrees of reinforcement and/or strength. The extrudate having a varying fiber reinforcement is deposited onto a mold core or cavity.

Abstract: A foamed thermoplastic resin fiber reinforced part is provided. The part comprises a member formed of thermoplastic resin, a plurality of cells and a plurality of reinforcing fibers dispersed within the member, and a skin formed on at least one exterior surface of the member. The skin is substantially devoid of cells. Here, the reinforcing fibers have a length of about 25 mm in an amount of about 10% by weight of the foamed thermoplastic resin fiber reinforced part. At least one of a cell density and a cell size of the plurality of cells is inversely proportional to the amount of the reinforcing fibers dispersed within the member.