A vehicle bumper (20) integrates rigid and flexible components into a
single
co-injection molded structure. In a preferred embodiment, a flexible fascia (58)
is provided with integrated rigid fastener brackets (62, 66, 70, 71), energy
absorption structure and head lamp brackets and housings (62). A method
for manufacturing such a bumper provides for the injection of two different plastic
materials during the same molding process. The flexible plastic material first
injected into the mold. Then, the rigid plastic material is injected at gates located
where the rigid material is desired. In one embodiment, the rigid material is completely
contained within the flexible material. The rigid material may be either a higher
stiffness plastic or a fiber reinforced plastic.