Instrument Panel Manufacturing

Hard Panels

Injection Molding

• Paint or Soft Paint
• Thermoplastic pellets to form a part
• Grain/texture imbedded in the substrate and painted
• Hard surface
• Consistent grain and gloss
• Typically lowest cost process for panels

The Hyundai Lavita with Visteon's Mold-in-Color Instrument Panel.

Mold-In-Color

• Color pigmented polypropylene
• Grain and texture in the substrate
• Hard surface
• Consistent color, grain and gloss
• Integrated passenger airbag
• Common tooling for vehicles with or without passenger airbag
• Cost-effective

Soft Panels

Foam In-Place

Negative Thermoforming

The Hyundai Tiburon with Visteon's Negative Thermoformed Instrument Panel

• Thermoforming of an ungrained sheet drawn into a cavity tool and formed by utilizing heat, vacuum and pressure
• Uses Thermoplastic Olefin (TPO) compact sheet or trilaminate
• Grain/texture in the tools
• Soft surface
• Lower gloss
• Superior craftsmanship to positive thermoforming
• Offers greater design flexibility
• Cost effective solution to powder slush molding
• Ten year durability
• Weight reduction
• Integrated airbags

 

Powder Slush Molding

The 2002 Ford Thunderbird with Visteon's Powder Slush Molded Instrument Panel

• Dispersion of resin powder onto a heated nickel shell cavity
• Uses polyvinyl chloride (PVC) or thermoplastic polyurethane (TPU)
• Grain/texture in the tool
• Soft surface
• Lower gloss
• Excellent grain quality and touch perception
• Offers greater design flexibility
• Extremely durable
• Integrated airbags

 

Positive Thermoforming

The Lincoln Continental with Visteon's Positive Thermoformed Instrument Panel

• A thermoformed roll sheet stock or sheet material is bonded to the substrate with an injected foam layer
• Uses PVC or TPO compact sheet
• Uses PVC or TPO trilaminate/bilaminate
• Grain/texture in covering
• Soft surface
• Lower gloss
• Greater design flexibility to injection molding
• Lower cost alternative to other foam in-place processes

 

Hard Panels with Select Soft Zones

Laminate Insert Molding

The Mazda Tribute with Visteon's Laminate Insert Molding

• Uses pre-formed laminate skin with horizontal molding press before the injection cycle
• Uses TPO trilaminate
• Grain/texture in the covering
• 100 percent recyclable
• Superior craftsmanship
• Multiple grains and textures
• Sharper radii, lines, logos and lettering
• Exceeds 10-year durability requirement
• Offers design flexibility and product differentiation
• Can be utilized on other interior trim components

Additional Information
Interactive Module - Cockpit Systems
Product Specifications - Cockpit Systems
Product Specifications - Instrument Panel
Feature Story - Cockpit Systems Design and Modeling
Feature Story - Cockpit Systems Testing
Feature Story - Negative Thermoforming
Feature Story - Cockpit Systems
Feature Story - Systems Integration Helps Deliver Just-in-Time
Feature Story - Mold-in-Color Instrument Panel
Capabilities - GENPAD®
Capabilities - In-Line Vehicle Sequencing