Method to make a composite automotive trim part

A process for making a composite part having a thickness comprising a textured skin and a rigid or foam substrate layer comprising the steps of:

• A) providing a molding apparatus comprising a mold having a first mold half having a textured surface and a second mold half being engageable with said first mold half to define therebetween a mold cavity corresponding to the thickness of said composite part;
• B) forming the textured skin on the surface of the first mold half by
• i) heating the first mold half,
• ii) applying an aqueous thermoplastic dispersion onto the heated first mold half textured surface,
• iii) forming a textured skin having a first textured surface in contact with the first mold half textured surface and a second surface opposite the first surface separated by a thickness,
• and
• iv) allowing the textured skin to dry on the first mold half, wherein the aqueous thermoplastic dispersion is derived from the melt blending of
• a) a thermoplastic composition in the presence of
• b) at least one dispersing agent, and,
• c) water;
• C) bringing the first mold half comprising the dry skin and second mold halve together with a gap the thickness of the composite part minus the thickness of the skin;
• D) forming the rigid or foam substrate layer between the first and second mold halves onto the second surface of the textured skin to form the composite part comprising a textured skin and a rigid or foam substrate layer;
• E) allowing the composite part to cool;
• F) opening the mold;
• and
• G) removing the composite part.