A method of making a body panel assembly for a vehicle, comprising the steps of: providing at least one first panel including predetermined weld surfaces; providing at least one second panel (14, 16) including predetermined weld surfaces; providing at least one infrared heating fixture having a plurality of infrared heat sources; providing a first tool nest and a second tool nest; loading the first panel onto the first tool nest; loading the second panel (14, 16) onto the first panel; moving the first tool nest and/or second tool nest to bring the second panel (14, 16) into contact with the second tool nest; retaining the second panel (14, 16) in the second tool nest as the first tool nest moves away from the second tool nest and/or as the second tool nest moves away from the first tool nest; aligning the at least one infrared heating fixture with the first tool nest and second tool nest; positioning the first tool nest and/or second tool nest into predetermined proximity to the at least one infrared heating fixture to align the plurality of infrared heat sources with the respective predetermined weld surfaces on the first and second panels (12, 14, 16); heating the predetermined weld surfaces of the first and second panels (12, 14, 16) via the plurality of infrared heat sources for a predetermined heating time; positioning the infrared heating fixture out of proximity with the first and second panels (12, 14, 16); bringing the first panel and second panel (14, 16) into contact with each other, via the first and/or second tool nests, with the heated corresponding weld surfaces on the first and second panels (12, 14, 16) aligned; and, applying a predetermined clamping pressure for a predetermined clamping time to the first and second panels (12, 14, 16) via the first and second tool nests forming a seal at the weld surfaces of the first and second panels (12, 14, 16); providing a first outer panel and a second outer panel including a finished part surface, said first outer panel and second outer panel (18, 20) are operably connected to the at least one second panel (14, 16), wherein the at least one second panel (14, 16) is a modular panel or an upper reinforcement panel to reinforce the body panel assembly for strength; and characterized by overmolding, in at least one location, a unidirectional tape into the modular panel and/or upper reinforcement panel to provide additional structure and tether the body panel assembly to take impact load. providing at least one first panel including predetermined weld surfaces; providing at least one second panel (14, 16) including predetermined weld surfaces; providing at least one infrared heating fixture having a plurality of infrared heat sources; providing a first tool nest and a second tool nest; loading the first panel onto the first tool nest; loading the second panel (14, 16) onto the first panel; moving the first tool nest and/or second tool nest to bring the second panel (14, 16) into contact with the second tool nest; retaining the second panel (14, 16) in the second tool nest as the first tool nest moves away from the second tool nest and/or as the second tool nest moves away from the first tool nest; aligning the at least one infrared heating fixture with the first tool nest and second tool nest; positioning the first tool nest and/or second tool nest into predetermined proximity to the at least one infrared heating fixture to align the plurality of infrared heat sources with the respective predetermined weld surfaces on the first and second panels (12, 14, 16); heating the predetermined weld surfaces of the first and second panels (12, 14, 16) via the plurality of infrared heat sources for a predetermined heating time; positioning the infrared heating fixture out of proximity with the first and second panels (12, 14, 16); bringing the first panel and second panel (14, 16) into contact with each other, via the first and/or second tool nests, with the heated corresponding weld surfaces on the first and second panels (12, 14, 16) aligned; and, applying a predetermined clamping pressure for a predetermined clamping time to the first and second panels (12, 14, 16) via the first and second tool nests forming a seal at the weld surfaces of the first and second panels (12, 14, 16); providing a first outer panel and a second outer panel including a finished part surface, said first outer panel and second outer panel (18, 20) are operably connected to the at least one second panel (14, 16), wherein the at least one second panel (14, 16) is a modular panel or an upper reinforcement panel to reinforce the body panel assembly for strength; and characterized by overmolding, in at least one location, a unidirectional tape into the modular panel and/or upper reinforcement panel to provide additional structure and tether the body panel assembly to take impact load.