Abstract: A method and apparatus for manufacturing a vehicular panel (10) with a region of weakness that permits the panel to deform at predefined locations in a prescribed manner in response to an incident force (F). The panel (10) has a substrate with an exposed surface (“A”) side (14), a hidden surface (“B”) side (12), and a core section (16) extending therebetween. The method comprises the steps of (I) molding the part; (II) optionally, curing the part; (III) placing the part in a holding fixture; (IV) securing the “A” surface opposite an area of the “B” surface in which a scoring step is to be performed; (V) applying a scoring tool to the “B” surface to define a scored part with one or more notches (18) that extend inwardly from the “B” surface into the core section so that the one or more notches are invisible when viewed from the “A” side of the part; and (VI) retracting the tool and removing the scored part from the fixture.

Abstract: The present invention relates to a two-shot, non-shut-off method of manufacturing a 100% grained trim component for a vehicle. The method includes actuating a tool insert between a mold cavity and a secondary void to form a molded trim component having a groove. A first shot of material is injected to form a first trim element having a grained class-A side. During the first shot, flash enters the secondary void to provide a non-shut-off condition. The tool insert is retracted to define a ditch in the first trim element. A second shot of material is injected to form a second trim element having a grained class-A side, during which time a portion of the second shot enters the ditch to provide a non-shut-off condition. The trim elements are then bonded where a portion the second trim element bonded to the first trim element within the groove.

Abstract: A mold assembly for forming a multi-shot molded part includes a mold system defining a mold cavity, and a retracting member disposed in the mold system selectively movable between extended and retracted positions in the mold cavity. A first molding material is injected in the mold cavity when the mold system is in a configuration with the retracting member in the extended position, forming a first portion of a molded part including a thin wall portion. A second molding material is injected in the mold cavity when the mold system is in another configuration with the retracting member in the retracted position, forming a second portion of the molded part and providing open cavity portions adjacent both surfaces of the thin wall portion. The second material penetrates the thin wall portion, filling the open cavity portions and forming a connection between the first and second portions of the molded part.