Instrument panel with integral hidden airbag door cover and method of in-process manufacture thereof

According to the present invention, an instrument panel cover (16) for use in an instrument panel (10) of a vehicle compartment (12) having a supplemental inflatable restraint (SIR) system (32) and a method for manufacturing the instrument panel cover (16) are provided. The instrument panel cover (16) includes a body having an inner surface (24) and an opposing outer surface (26), the body having an air bag cushion deployment region (18) formed in the inner surface (24) thereof, the deployment region (18) being defined by at least one score (20) formed in the inner surface (24) to a predetermined depth, wherein the at least one score (20) is formed by at least one scoring member (43) which contacts the instrument panel cover (16) during the manufacture thereof and the advancement of the at least one scoring member (43) causes the instrument panel cover (16) to thin out in predetermined locations which define the at least one score (20). Because the present invention incorporates the scoring process into the process for forming the instrument panel cover (16), the present invention advantageously eliminates the need of secondary scoring of the air bag door seam and therefore provides cost benefits and a reduction in processing and manufacturing times.