Dashboards and instrument panels

Modern dashboards (instrument panels) are composite parts of three main layers: exterior skin (the visible and tactile surface, typically TPU, PVC or PU spray skin), intermediate foam (semi-rigid foam providing impact absorption and soft touch) and structural substrate (generally injection-molded plastic or composite, providing structural rigidity and fixation points).

When PU spray skin is used, the process is: PU skin is spray-applied in a heated mold (forming the surface with the desired texture); semi-rigid foam is injected behind the skin, filling the space between skin and substrate; the part is demolded as a single assembly. This technique produces dashboards with premium appearance — leather texture, soft touch, impact absorption — characteristic of premium and upper-entry vehicles.

Alternatively, pre-formed TPU skin can be used (injection-molded or thermoformed separately), with conventional injected foam and mechanical assembly to the substrate. Each technology has cost, quality and design flexibility advantages.

The intermediate foam is typically semi-rigid, density 80 to 150 kg/m³ — firmer than seat foam but with some compressibility. It provides impact absorption in case of collision (safety requirement), soft touch (comfort requirement) and integration of sensors/airbags when applicable.