Airbag door and method for making same

An airbag door system having an airbag door portion and a trim member portion, said airbag door system comprising:

• a substrate comprising a substrate upper surface, a substrate lower surface, a substrate thickness and a substrate line of mechanical weakness, said substrate line of mechanical weakness comprising at least one substrate aperture at least partially separating said substrate into an airbag door substrate portion and a trim member substrate portion;
• an outer shell comprising an outer shell upper surface, an outer shell lower surface, an outer shell thickness and an outer shell line of mechanical weakness, said outer shell line of mechanical weakness comprising an outer shell reduced thickness portion defined by an outer shell sever extending partially through said outer shell thickness from said outer shell lower surface towards said outer shell upper surface, said outer shell line of mechanical weakness at least partially separating said outer shell into an airbag door outer shell portion and a trim member outer shell portion;
• a foam disposed between said substrate and said outer shell, said foam comprising a foam upper surface, a foam lower surface, a foam thickness and a foam line of mechanical weakness, said foam line of mechanical weakness comprising a foam reduced thickness portion defined by a foam sever extending partially through said foam thickness from said foam lower surface towards said foam upper surface, said foam line of mechanical weakness at least partially separating said foam into an airbag door foam portion and a trim member foam portion;
• said outer shell line of mechanical weakness comprising a line 6f mechanical weakness being laterally displaced by at least 3.0 millimeter relative to said foam line of mechanical weakness or said substrate line of mechanical weakness;
• and wherein said outer shell sever comprises first and second outer shell sever surfaces, said outer shell sever sufficiently narrow such that at least a portion of said first and second outer shell sever surfaces are in direct contact with one another after said outer shell sever is formed.