Method and apparatus for blind stitching a formed component and components formed from the method

A method of applying stitching to an interior component, comprising an outer skin layer with a contoured surface, a substrate layer and an intermediary layer located between the contoured surface of the outer skin layer and the substrate layer, the method comprising:

• a) penetrating the contoured surface of the outer skin layer at an entry point on a first surface of the outer skin layer with a curved needle;
• b) exiting the contoured surface of the outer skin layer at an exit point on the first surface with the curved needle, wherein the steps of penetrating and exiting cause a thread to pass through the entry point and the exit point on the contoured surface of the outer skin layer;
• c) grabbing the first thread with a hook located proximate to the exit point;
• d) retracting the needle through the exit point and the entry point while pulling a second thread through the exit point via the first thread to form a stitch;
• e) advancing the contoured surface of the outer skin layer to a new location with respect to the needle and hook;
• and
• f) repeating steps a-e until a predetermined amount of stitches are applied to the contoured surface of the outer skin layer.

A method of applying stitching to an interior component, comprising an outer skin layer with a contoured surface and a foam layer applied thereto, the method comprising:

• a) penetrating the contoured surface of the outer skin layer at an entry point on a first surface of the contoured surface of the outer skin layer with a curved needle;
• b) exiting the contoured surface of the outer skin layer at an exit point on the first surface with the curved needle, wherein the steps of penetrating and exiting cause a thread to pass through the entry point and the exit point on the contoured surface of the outer skin layer and wherein the foam layer is applied to a second surface of the contoured surface of the outer skin layer, the second surface being opposite the first surface and wherein the needle also passes through a portion of the foam layer as it travels through the entry point and the exit point;
• c) grabbing the first thread with a hook located proximate to the exit point;
• d) retracting the needle through the exit point and the entry point while pulling a second thread through the exit point via the first thread to form a stitch;
• e) advancing the contoured surface of the outer skin layer to a new location with respect to the needle and hook;
• and
• f) repeating steps a-e until a predetermined amount of stitches are applied to the contoured surface of the outer skin layer.