Overmolded Manifold O-Ring

A method of making an O-ring in a respiratory access assembly, comprising the steps of:

• providing a distal plate having a port, the port adapted to be positioned in operable communication with an artificial airway of a patient;
• providing a proximal plate including a first port and a second port, the distal plate positioned against the proximal plate in a stacked configuration, each plate configured to move;
• providing an actuator positioned adjacent to at least one plate, the actuator cooperating with at least one plate to permit movement of at least one plate when the actuator is positioned in a movement-enabling position, the actuator cooperating with both plates to lock the plates in a fixed position when the actuator is positioned in a locked position, such that the plates are locked into a predetermined position relative to each other, the actuator including a blocking portion in a side opening which is configured to extend into at least one port when the actuator is positioned in the movement-enabling position, and to withdraw from the one port when the actuator is positioned in the locked position;
• wherein said blocking portion moves slidably within an O-ring which prevents loss of pressure around said blocking portion from said artificial airway;
• providing a channel in said proximal plate for the injection of a thermoplastic elastomer;
• providing an insert that mimics the dimensions and location of said blocking portion in said side opening, to create a void space that matches the desired dimensions of the O-ring;
• and
• injecting said thermoplastic elastomer into said channel and forming said O-ring.