On Mon, 15 May 2006 09:48:38 -0600, Ed Huesers wrote:

I have a customer wanting to make a large ridged part and I'm
thinking a foam part would work good. I've searched groups google here
and found nothing.
I'm thinking the kind of process they use in the auto industry to
make the foam dash with the skin formed on it by baking the part. Does
anyone know the name of the process used to make these types of
foam/skinned parts.
I'm wondering what kind of molds are used and what foams can be used.

One other molding process not yet mentioned is rotational molding. The
"skin" can be (within limits) as thick or as thin as you want. Foam can
be done in the mold via a drop box to release a foaming agent after the
outer layer has formed. Or after de-molding with the same two part foam
others have suggested.
--
William