Method of molding complex structures and an enclosure cover made by said method

An enclosure comprising:

• a body;
• and
• a cover configured to form an enclosed volume when the cover is attached to the body, the cover including:
• an upper wall;
• a lower wall having an exterior portion and an interior portion, the interior portion overlapping the upper wall;
• lateral walls connecting the upper wall to the lower wall;
• and
• an intermediate wall connecting the upper wall to the lower wall, the intermediate wall extending between the lateral walls;
• a bottom wall connecting the lateral walls and the lower wall;
• and
• a top wall connecting and extending between the lateral walls, the top wall being connected to the upper wall and having a common edge therewith,
• wherein the lateral walls, the top wall, the bottom wall, the exterior portion of the lower wall, the intermediate wall, and the upper wall have exterior surfaces and interior surfaces, the interior surfaces defining a volume of the one-piece part, and
• wherein the interior portion of the lower wall extends into said volume.

A method of forming a one-piece part, the method comprising:

• providing a mold comprising a top die, a bottom die, and a slide including a head and a stem, the head having an upper surface, an intermediate surface, and a lower surface, and the top die comprising an upper surface, an intermediate surface, and a lower surface;
• positioning the bottom die and the slide adjacent the top die with the intermediate surface of the head of the slide adjacent the intermediate surface of the top die;
• filling the cavity with material;
• waiting until the material to solidifies;
• moving the slide away from the intermediate surface of the top die until the lower surface of the slide clears the interior portion of the lower wall;
• separating the top die and the bottom die;
• and
• releasing the one-piece part from the bottom die or the top die,
• wherein the one-piece part comprises an upper wall, a lower wall having an exterior portion and an interior portion, the interior portion overlapping the upper wall, lateral walls connecting the upper wall to the lower wall, a top wall connecting and extending between the lateral walls, the top wall being connected to the upper wall and having a common edge therewith, a bottom wall connecting the lateral walls and the lower wall, and an intermediate wall connecting the upper wall to the lower wall, the intermediate wall extending between the lateral walls, wherein the lateral walls, the exterior portion of the lower wall, the intermediate wall, the top wall, the bottom and the upper wall have exterior surfaces and interior surfaces, the interior surfaces defining a volume of the one-piece part, and wherein the interior portion of the lower wall extends into said volume.