Abstract: A method of fabricating a plurality of seat elements is provided. The plurality of seat elements are styled to have a range of styling features. The method includes a step of determining the range of styling feature by selecting characteristics of a middle ply of foam and/or the exterior ply of the trim cover and selecting a number and position of panels that are sewn to form the trim cover. The seat elements are fabricated on a common mold apparatus.

Abstract: A mold tool (16) for forming a trim covered foam substrate of a seat assembly comprises an upper mold cast (18) defining an upper mold surface (19) and a lower mold cast (20) defining a lower mold surface (2). A split line (28) is defined adjacent to the upper and lower mold surfaces between the upper mold cast and the lower mold cast when the mold casts are in facing mating engagement forming a mold cavity (22) therebetween. A plurality of heat lines (24) extend through the upper (18) and lower (19) mold casts adjacent the respective upper and lower mold surfaces for heating the mold cavity (22). A cooling line (30) extends through at least one of the upper and lower mold casts adjacent the split line (28) for cooling the split line of the mold tool.