Patent ID: 7572401

Claim:
A method of making an automobile interior door panel, said method comprising: a) providing a molding tool comprising a first mold half and a second mold half, the first and second mold halves cooperating to form a first mold cavity; b) providing a bolster within the first mold cavity, the first mold half, the second mold half, and the bolster cooperating to form a second mold cavity; c) introducing a first resin into the second mold cavity, the resin, upon cooling, forming a door panel sub assembly, the door panel sub assembly comprising a door panel portion secured to the bolster, the door panel portion having a first upper door panel portion above the bolster and a lower door panel portion below the bolster; d) providing the door panel sub assembly within the first mold half and a third mold half, the first mold half, the third mold half, and the door panel sub assembly forming a third mold cavity; and e) introducing a second resin less rigid that the first material into the third mold cavity, the second resin, upon cooling, forming a second upper door panel portion over and secured to the first upper door panel portion, wherein the bolster includes a peripheral flange, the first upper door panel portion including a first main panel portion extending away from the flange and a first finger portion extending over the flange and the lower door panel portion including a second main panel portion extending away from the flange and a second finger portion extending over the flange.