Method and apparatus for continuous injection molding

A method for forming extended strips having a non-constant cross-section, the method comprising:

• providing a molten molding material to a single rotating shaping wheel that includes a molding template having features thereon suitable for forming desired features in the molding material, thereby forming a continuous strip having a non-constant cross section;
• flattening the molten material within the shaping wheel as the shaping wheel rotates;
• affirmatively cooling the flattened strip while the strip is on the shaping wheel, wherein the cooling transforms the molding material to a second state;
• deflashing the extended strip while it remains on the shaping wheel;
• removing the deflashed flattened strip from the shaping wheel;
• passing the removed strip over a reshaping wheel arranged to substantially remove a curvature from the strip that is imparted by the shaping wheel thereby straightening the continuous strip;
• and
• cutting the strip into extended strips.