High range fascia fabricating method for vehicle, involves molding intermediate foam layer by injecting foam between support layer and skin, withdrawing insert from recess, and fixing decoration piece inside recess

摘要

The method involves temporarily placing an insert in a thermoforming mold for locally modifying a wall of the mold, and thermoforming a conformed skin in the mold. The skin is extracted from the mold after cooling, where the skin has a recess (9) on its external wall (7) for receiving the insert. The skin carrying the insert is transferred into a foaming mold containing a support layer (2). An intermediate foam layer (3) is molded by injecting foam between the support layer and the skin. The insert is withdrawn from the recess, and a decoration piece (6) is fixed inside the recess. An independent claim is also included for a fascia comprising an intermediate foam layer.