Method for rotationally molding an article with a vulnerable insert

A method for molding a solid article from both solid-forming and foam-forming reactive liquid polymer materials, said article having a first molded component and a second molded component and said article incorporating at least one vulnerable insert, said method comprising the steps of:

• providing a controllably spinnable platen having temperature controllable first and second cavity molds mounted alternately thereon and means for distributing said liquid polymer material into said molds;
• securing said insert stably and insulatedly within said first mold;
• introducing said solid-forming polymer material into said means for distributing said polymer material;
• spinning said platen at a controlled rotational speed and controlled temperature to move said solid-forming polymer material into said first mold without distorting said insert;
• curing said solid-forming polymer material to form said first molded component and to incorporate and bond said insert into said first molded component;
• removing a replaceable first mold top of said first mold from a common mold bottom and replacing said first mold top with a second mold top coupled with said common mold bottom to form said second mold, thus maintaining said first molded component secured within said common mold bottom;
• introducing said foam-forming polymer material into said means for distributing said polymer material;
• spinning said platen at a controlled speed and temperature to move said foam-forming polymer material into said second mold without distorting said insert;
• curing said foam-forming polymer material to form said second molded component and to bond said first molded component with said second molded component to form said solid article;
• and
• removing said article with said insert incorporated therein from said second mold.