A method of making an integrated inner trim panel for a vehicle door and
an inner trim panel made thereby are disclosed. The method includes
sequentially spraying a skin layer, a padding layer, and applying a
structural layer in an open mold that defines the facing surface of the
inner panel of a door. The integrated inner trim panel may be provided
with areas of greater and lesser padding. The skin layer may be formed
from a reactant mixture of polyurethane. The padding layer may be a foam
polyurethane composition. The structural layer may be a glass-reinforced
polyurethane reactant mixture. The inner door panel is an integrated
layered structure including a skin layer, a padding layer, and a
structural layer. The padding layer may be varied in thickness to provide
selectively variable padding in predetermined areas.