Abstract: In one embodiment a method for creating a molded-in-color vehicle panel is provided. The mold may have at least first and second mold members, each having a forming surface for forming a portion of the vehicle panel. One mold member may translate relative to the other to collectively receive a heated resin with a molded-in-color to form the vehicle panel. The resin may be formed into a solid molded-in-color interior vehicle panel. After allowing the resin to partially cool, an aperture may be formed by punching through in the molded-in-color resin with a punch.

Abstract: In one embodiment, a method for molding a molded-in-color panel in a mold includes providing a mold having a first mold member and a second mold member. One of the first mold member and the second mold member has an appearance portion forming surface and the other of the first mold member and the second mold member has a concealed portion forming surface corresponding with the appearance portion forming surface. The concealed portion forming surface forms a concealed portion of a panel and is free of any protuberances and ancillary structural members for facilitating ideal surface characteristics of an appearance portion of the panel. Molded-in-color resin is injected in the mold and cooled to form a molded-in-color panel. At least one ancillary structural member is welded to the concealed portion of the panel.

Abstract: In one embodiment a method for creating a molded-in-color vehicle panel is provided. The mold may have at least first and second mold members, each having a forming surface for forming a portion of the vehicle panel. One mold member may translate relative to the other to collectively receive a heated resin with a molded-in-color to form the vehicle panel. The resin may be formed into a solid molded-in-color interior vehicle panel. After allowing the resin to partially cool, an aperture may be formed by punching through in the molded-in-color resin with a punch.

Abstract: A chilled air pressure box is provided for thermoforming a plastic sheet. The chilled air pressure box comprises a box, a box perimeter, an inlet valve, a compressed air source and a chilled air source. The box has an interior space within the box and defines an inlet opening. The box perimeter is for sealingly interfacing with a vacuum mold. The inlet valve is substantially disposed within the interior space, adjacent and aligned with the inlet opening such that when the inlet valve is closed the inlet opening is substantially sealed and when the inlet valve is opened the inlet opening is not sealed. The compressed air source is capable of pressurizing the interior space with compressed air and interfaces with the box. The chilled air source communicates with the inlet opening.

Abstract: In one embodiment, a method for molding a molded-in-color panel in a mold includes providing a mold having a first mold member and a second mold member. One of the first mold member and the second mold member has an appearance portion forming surface and the other of the first mold member and the second mold member has a concealed portion forming surface corresponding with the appearance portion forming surface. The concealed portion forming surface forms a concealed portion of a panel and is free of any protuberances and ancillary structural members for facilitating ideal surface characteristics of an appearance portion of the panel. Molded-in-color resin is injected in the mold and cooled to form a molded-in-color panel. At least one ancillary structural member is welded to the concealed portion of the panel.

Abstract: In one embodiment a mold for creating a molded-in-color vehicle panel is provided. The mold may have at least first and second mold members, each having a forming surface for forming a portion of the vehicle panel. One mold member is translatable relative to the other to collectively receive a heated resin with a molded-in-color to form the vehicle panel. At least one punch is provided within one of the first or second mold members. The at least one punch is actuatable to extend through the one forming surface of and is actuatable to extend through a nest to nest in the other forming surface for forming an aperture through a partially cooled vehicle panel.

Abstract: A chilled air pressure box is provided for thermoforming a plastic sheet. The chilled air pressure box comprises a box, a box perimeter, an inlet valve, a compressed air source and a chilled air source. The box has an interior space within the box and defines an inlet opening. The box perimeter is for sealingly interfacing with a vacuum mold. The inlet valve is substantially disposed within the interior space, adjacent and aligned with the inlet opening such that when the inlet valve is closed the inlet opening is substantially sealed and when the inlet valve is opened the inlet opening is not sealed. The compressed air source is capable of pressurizing the interior space with compressed air and interfaces with the box. The chilled air source communicates with the inlet opening.