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My amateur theory is a plastic door would be too flimsy to seal when warm, solid metal door too heavy for movement mechanism and probably noisey when closing. The foam softens and lightens the door. A solid door would block all air one direction or the other when/if it fails, when the foam is gone you at least get 'some' air where it needs to go. There's probably a cost factor too.
Foam covered blend doors seem fairly common, at least on VAG cars. I think my Dodge pickup does as well as its been shooting black foam out the vents just like the boxster. Haha.
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1998 Porsche Boxster Base - 2005 Volvo S60R AWD - 2003 Subaru Wrx Wagon - 2003 Jeep Wrangler Rubicon - 1992 Subaru Loyale Wagon w/4in Lift - 2004 Dodge Ram 2500
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