System and method for forming an oral care implement

A system for forming an oral care implement comprising a base structure having a handle portion and a head portion, the system comprising:

• a first mold defining a first mold cavity having a first mold cavity axis, the first mold cavity comprising a first portion that corresponds to the handle portion of the base structure and a second portion that corresponds to the head portion of the base structure;
• a first injection orifice formed into the first mold and providing a first passageway directly into the first portion of the first mold cavity;
• a second injection orifice formed into the first mold and providing a second passageway directly into the first portion of the first mold cavity, the second injection orifice spaced apart from the first injection orifice;
• a first hot runner sub-system fluidly coupled to the first injection orifice;
• a second hot runner sub-system fluidly coupled to the second injection orifice;
• wherein the system is configured to dispense the first material into the first portion of the first mold cavity via the first injection orifice with the first hot runner sub-system, and after passage of a predetermined period of time, to subsequently dispense the second material into the first portion of the first mold cavity via the second injection orifice with the second hot runner sub-system, the second material being injected into the first material to displace the first material, thereby forming the base structure such that the second material forms a core component of the base structure and the first material forms a shell component of the base structure that surrounds the core component;
• wherein the first and second materials collectively form the head portion and the handle portion of the base structure, and wherein a portion of an exposed outer surface of the handle portion of the base structure that is aligned with the second injection orifice of the first mold is formed of the second material, a remainder of the exposed outer surface of the base structure being formed of the first material;
• and
• a second mold defining a second mold cavity, and wherein the system is further configured to dispense a third material into the second mold cavity when the base structure of the oral care implement is positioned in the second mold cavity, the third material covering the portion of the exposed outer surface of the handle portion of the base structure that is formed of the second material.