there is disclosed a process for manufacturing a padded element . the process comprises the steps of placing a trim cover on a mandrel , the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer ; heating the trim cover to a temperature sufficient to shape the thermoformable foam layer ; shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover ; transferring the shaped trim cover from the mandrel to a lower mold having shape substantially complimentary to the shaped trim cover ; placing an upper mold over the lower mold to define a mold cavity ; dispensing a liquid foamable polymeric composition in the mold cavity ; and expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element .