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An instrument panel (12) includes a thermoplastic base substrate (54), with at least one tear seam notch (60) pressed into a first surface (56) of the base substrate. At least one consolidated area (66) is pressed into a second surface (58) of the base substrate. The at least one consolidated area is aligned with the at least one tear seam notch. The instrument panel further includes at least one hinge area (74). Each hinge area is an area of low consolidation where a thickness of the base substrate at the low consolidation area is greater than a thickness of the base substrate at the consolidation area. The at least one tear seam notch and the at least one hinge area define at least one airbag door (78). (FIG). 3