Multi-stage insert molding method

A multistage method of insert molding, comprising the steps of:

• providing a vertically moveable first mold member having a lower end with a cavity formed therein;
• providing a second mold member having a substantially flat upper molding surface;
• providing a third mold member having an upper end with a cavity formed therein;
• positioning an insert directly on said flat upper molding surface of said second mold member;
• positioning said first mold member with respect to said second mold member so that said cavity of said first mold member receives said insert;
• injecting a first flowable plastic material into said cavity in said first mold member to partially encapsulate said insert;
• allowing the first flowable plastic material to cool and solidify, thereby creating a first stage molding with said insert partially encapsulated therein;
• removing said first mold member and said first stage molding with said insert partially encapsulated therein from said second mold member;
• positioning said first mold member with respect to said third mold member so that said first stage molding with said insert partially encapsulated therein registers with said cavity in said third mold member;
• injecting a second flowable plastic material into said cavity in said third mold member;
• allowing the second flowable plastic material to cool and solidify to form a second stage molding wherein said insert is sandwiched between said first stage molding and said second stage molding and is completely embedded therebetween;
• and ejecting said (second stage molding) completely embedded insert from said cavities in said first and third mold members.