A method of forming an invisible frangible tear seam in a multi-layered vehicle trim panel for deployment of an air bag therethrough. The method involves the use of a jig or mask that is configured in the desired shape of the tear seam. The tear seam is produced by providing a first polymeric layer on a trim panel mold surface and then positioning the jig or mask on the first polymeric layer. Next a second polymeric layer is applied to the first polymeric layer using a spray process. After the second polymeric layer has been applied the jig or mask is removed, leaving a foot-print of the jig or mask which defines the tear seam. The resulting bi-layered structure is joined to a support panel using an adhesive foam to form a multi-layered vehicle trim panel.