Abstract: A filled aliphatic thermoplastic urethane automotive air bag door tear seam insert is formed of a polyol, a chain extender, an organic diisocyanate, an antioxidant, a urethane catalyst, and a weakening filler wherein the filler is present in a range of approximately 60% to 80% by weight and is selected from the group consisting of anhydrous calcium sulfate, nepheline syenite and hollow silica-alumina alloy microspheres and combinations thereof. The filler may be only one of the group members or any combination thereof and in either equal or unequal proportions. The insert is adapted to be molded in place in a cover skin cast there about. The cast cover skin including the tear seam insert may be coated with a light stable paint; or for light stability and color matching, the urethane elastomer forming the cover skin and insert is formulated to include an ultra violet stabilizing agent(s) and a color pigment(s) in certain critical concentrations to obtain the desired effect.