Abstract: A relatively flexible thermoplastic air bag cover assembly having a switch and method of manufacturing same is provided including a thermoplastic electromagnetic material which forms welds between front and back panels of the assembly. The welded front and back panels define a switch pocket therebetween to hold the switch such as a membrane-type horn switch therein. The welds occupy a relatively small amount of surface area yet provide strong polymer-to-polymer linkages between the front and back panels, thereby enlarging the effective switch activation area on the outer surface of the front panel. The welds are located very close to the switch pocket without damaging the switch during manufacturing. The bonds provided by the welds between the front and back panels are strong enough to prevent the switch from exiting the switch pocket during air bag deployment.