Abstract: A composite thermoplastic sheet includes, in an exemplary embodiment, a permeable core layer having a first surface and an opposing second surface. The core layer includes a plurality of reinforcing fibers bonded together with a first thermoplastic material. The composite sheet also includes a flexible thermoplastic skin laminated to and covering at least a portion of the first surface of the core layer. The core layer includes about 20 weight percent to about 80 weight percent reinforcing fibers.

Abstract: A composite thermoplastic sheet includes, in an exemplary embodiment, a permeable core layer having a first surface and an opposing second surface. The core layer includes a plurality of reinforcing fibers bonded together with a first thermoplastic material. The composite sheet also includes a flexible thermoplastic skin laminated to and covering at least a portion of the first surface of the core layer. The core layer includes about 20 weight percent to about 80 weight percent reinforcing fibers.

Abstract: An instrument panel (12) includes a thermoplastic base substrate (54), with at least one tear seam notch (60) pressed into a first surface (56) of the base substrate. At least one consolidated area (66) is pressed into a second surface (58) of the base substrate. The at least one consolidated area is aligned with the at least one tear seam notch. The instrument panel further includes at least one hinge area (74). Each hinge area is an area of low consolidation where a thickness of the base substrate at the low consolidation area is greater than a thickness of the base substrate at the consolidation area. The at least one tear seam notch and the at least one hinge area define at least one airbag door (78).