Abstract: A composite molded article and a method of fabricating such an article is disclosed, which is especially well-suited for forming one-piece interior vehicle panels, by way of a single molding operation, wherein the one-piece interior panel can be easily installed as a unit within the vehicle. In the fabrication of the one-piece molded composite article, a deformable sheet material, such as vinyl, is positioned on a female molding surface and drawn into conformity with the female molding surface of the mold cavity, either with or without preheating or vacuum forming. The mold apparatus is closed and a first moldable material is introduced into the mold assembly, with certain predetermined portions thereof being blocked off. Subsequently, a second moldable material is introduced at least into the predetermined areas previously blocked off during the introduction of the first moldable material.

Abstract: The plastic molded article is produced by heating a mold by contact with a preheated salt bath. The salt bath is readily maintained at a uniform temperature and is self-insulating for energy efficiency. A noncontact infrared sensor monitors the mold cavity temperature while in the salt bath, and the mold is removed from the bath when the proper mold temperature is reached. A charge of plastic powder is introduced into the mold by clamping the mold to a powder slush box with the mold cavity confronting the opening of the box. The mold and box are then simultaneously rotated to pour the plastic charge into the mold. The plastic charge forms a skin on the cavity surface and additional plastic material may be built up to provide additional thickness. The mold and box are then separated; the mold is then postcured and cooled, whereupon the finished article may be removed from the mold.