Injection modling methods, tooling, and products

An injection molding tool comprising:

• a first mold portion;
• a second mold portion;
• a first insert mounted on the first mold portion, the first insert having a protrusion that forms a gap with a sidewall of the second mold portion when the mold portions are closed;
• and
• a second insert replaceable with the first insert, the second insert lacking the protrusion.

A method for producing parts with an aperture and parts without an aperture using a single injection molding tool, comprising:

• providing an injection molding tool having a first mold portion, a second mold portion, and a cavity defined between the first mold portion and the second mold portion when closed, the cavity defining a shape of a molded part;
• installing a first insert on the first mold portion, the first insert having a protrusion that forms a gap with a sidewall of the second mold portion when the mold portions are closed, wherein the protrusion does not create a shutoff against the mold;
• injecting material into the cavity, the material having a melt flow rate below a predefined threshold, thereby forming a part with an aperture due to presence of the protrusion and the gap, where the aperture is free of flashing;
• opening the mold and removing the part with an aperture;
• replacing the first insert with a second insert, the second insert lacking the protrusion;
• injecting material into the cavity with the second insert installed, thereby forming a part without an aperture;
• and
• opening the mold and removing the part without an aperture.