Method of producing a modular cover for an air bag assembly

A method of producing a modular cover having a main portion with a lower edge, a step portion extending inwardly from the lower edge of the main portion, a vertical portion extending from the step portion in a direction away from the main portion, and a welting portion projecting parallel to the vertical portion from the lower edge of the main portion, said method comprising:

• preparing a first mold for defining inner surfaces of the main portion, the step portion and the vertical portion,
• preparing a second mold situated adjacent to the first mold, said second mold defining outer surfaces of the vertical portion, the step portion and the welting portion and having a submarine gate therein, said submarine gate having an outlet located at a side of the welting portion facing the vertical portion without facing a side of an outer surface of the main portion,
• preparing a third mold situated above the second mold for covering the first mold to thereby define the outer surface of the main portion so that a cavity of the modular cover with the welting portion is defined by the first, second and third molds,
• injecting a resin into the cavity through the submarine gate to form the modular cover,
• removing the first, second and third molds to take out a molded moduler cover, and
• cutting a projection formed at a position corresponding to the submarine gate so that when the modular cover is installed in a mounting plate in use, a gate mark formed by cutting the projection is located between the welting portion and the vertical portion and is hidden.