Method and apparatus for manufacturing a cuffed medical device

A method of manufacturing a medical airway device having a cuff, the method comprising:

• providing an injection molding apparatus loaded with a thermosetting elastomeric material, the injection molding apparatus comprising an injection nozzle;
• providing an injection mold comprising a sprue bush and a mold cavity, the sprue bush defining a sprue passage in fluid communication with the mold cavity;
• positioning the injection nozzle relative to the sprue bush such that a portion of the injection nozzle contacts, or is in proximity to, a portion of the sprue bush;
• shaping the cuff by injecting the thermosetting elastomeric material from the injection nozzle through the sprue passage and into the mold cavity;
• forming the cuff by curing the thermosetting elastomeric material within the mold cavity and at the same time preventing premature curing of residual thermosetting elastomeric material within the injection nozzle by applying heat to the thermosetting elastomeric material within the mold cavity while cooling the injection nozzle with a cooling fluid;
• and
• attaching the formed cuff to an airway tube.