Method of molding using mold inserts and apparatus therefor

An injection molding apparatus, comprising:

• a stationary half comprising:
• a resin mold surface,
• an opening in the resin mold surface defining a gate, and
• an injection passage extending from the gate through a thickness of the stationary half;
• an injector for introducing a first molding material through the injection passage and into a first molding cavity;
• a moving half disposed opposite the stationary half;
• movable mold inserts integrated in the stationary half and respectively define insert molding surfaces and an insert pressing surfaces,
• wherein the movable mold inserts are configured to move toward and away from the moving half, and
• wherein the insert molding surfaces and the moving half face one another,
• wherein a side of the first molding cavity is formed by the insert molding surfaces and the resin mold surface, and
• a movable insert actuator in mechanical communication with the stationary half and the insert pressing surfaces of the movable mold inserts,
• wherein the movable insert actuator is configured to move the movable mold inserts, thereby adjusting a molding cavity shape, a molding cavity depth, a molding cavity volume, or a combination comprising at least one of the foregoing;
• and
• a movable center mold portion is located between the stationary half and the moving half,
• wherein the movable center mold portion is configured to move, by slide, swivel or rotate, a formed part from the first molding cavity, between the movable center mold portion and the stationary half, to a second molding cavity, between the movable center mold portion and the moving half;
• and
• the moving half including a hot runner system that forms a ribbed structure mold in the movable half, wherein the hot runner system is configured to inject a second molding material onto the formed part to form a ribbed part that is over-molded onto the formed part.