Aspects of the present invention include interior vehicle trim panel having a sprayed expanded polyurethane layer and method of making same. In at least one embodiment, the method of making the vehicle interior trim panel comprises providing a skin layer on a spray tool, spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer, and securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim panel.