Automated Process for Fabricating Oral Care Implements

A method for forming a toothbrush body, the method comprising:

• providing a molding fabrication cell including a cluster of process machines arranged around a central area, an articulated robotic arm rotatably mounted in the central area, and a programmable controller automatically controlling movement and operation of the robotic arm;
• molding a batch of injection molded toothbrush skeletons in a first injection molding machine from a first material;
• rotating the robotic arm to the first injection molding machine;
• the robotic arm transferring the batch of skeletons to a cooling machine;
• cooling the batch of skeletons;
• the robotic arm transferring and inserting a first partial-batch of cooled skeletons into a second injection molding machine;
• overmolding a second material onto the first material of the first partial-batch of cooled skeletons in the second injection molding machine;
• the robotic arm transferring and inserting a second partial-batch of cooled skeletons into a third injection molding machine;
• and
• overmolding the second material onto the first material of the second partial-batch of cooled skeletons in the third injection molding machine.

A method for forming a toothbrush body, the method comprising:

• providing an articulated robotic arm having a first engagement feature configured and operable to engage a toothbrush body and a second engagement feature configured and operable to engage a toothbrush body;
• engaging a first toothbrush body with the first engagement feature of the robotic arm;
• moving the first toothbrush body to a first toothbrush forming machine with the robotic arm;
• engaging a second toothbrush body at the first toothbrush forming machine with the second engagement feature of the robotic arm;
• removing the second toothbrush body from the first toothbrush forming machine with the robotic arm while retaining the first toothbrush body with the first engagement feature;
• and
• inserting the first toothbrush body into the first toothbrush forming machine with the robotic arm.