Expandable molding insert apparatus and method

A controllably expandable molding insert for the creation of passageways through hardened cast components formed by molding component substrate within a mold, comprising:

• an inner shaft, having a length, with respective opposite ends and with external threading over at least a portion of such length thereof;
• an outer jacket having a central bore for receipt of said inner shaft, said outer jacket formed of compressible material having a predetermined hardness;
• and
• compression means, for selectively providing axial compression, and release of such compression, to said outer jacket, for moving said outer jacket between a first axially uncompressed position thereof having a first outer diameter, and a second axially compressed position thereof having a second, larger outer diameter, whereby placing said outer jacket in said axially first uncompressed position thereof after hardening of a component cast around said insert in an associated mold facilitates withdrawal of said insert from such associated mold.

A method for forming conduits within molded components, comprising:

• providing a mold for formation of a molded component therein;
• positioning in such mold an insert apparatus expandable between a first uncompressed position with a first diameter and a second compressed position with a second, larger diameter due to axial decompression and compression, respectively, of the insert apparatus;
• axially compressing the insert apparatus to establish the second, larger diameter thereof;
• and
• pouring component formation materials into such mold.