Abstract: A gas assisted method for molding a substrate is described, as a well as an apparatus for performing this molding process. Generally, this molding method will involve using a mold with a core side and a cavity side. The mold is designed to mold a substrate when filled with the thermoplastic. A quantity of thermoplastic is injected into the mold. Once the plastic is in the mold, gas is vented to the core side of the mold as the thermoplastic cools. The gas is introduced via sintered vents that have been added to the mold. In general, the gas will have a pressure less than 500 psi. Once the thermoplastic cools, the substrate is formed and can be ejected from the mold.

Abstract: A new type of airbag cover and method for making the same is described herein. The airbag cover will generally have an insert that includes one or more logos, indicia, symbols, trademarks, etc. that denote the vehicle manufacturer. A base will then be molded around this insert. The base and the insert are made of the same (or substantially the same) materials. However, the color used for the insert will differ from the color used for the base. The fact that different colors are used means that the indicia on the insert will be visually appealing and “eye-catching” to the consumer. Once the base is molded to the insert, these two features will chemically bond together. The indicia and the base material may be chemically and/or mechanically bonded together. Generally, this bonding is accomplished such that there is a continuous fit between the insert and the base.