Seamless insert molding techniques

A method for forming a portable computing device housing, comprising:

• obtaining a single piece first body formed of a first material and comprising a first external surface having first edges that define a first opening, the first external surface transitioning to first side walls having a first set of bonding surfaces;
• injection molding a molten molding material directly to a first body formed of a first material and comprising a first external surface having first edges that define a first opening, the first external surface transitioning to first side walls having a first set of bonding surfaces, wherein the molten molding material contacts the first body along the first set of bonding surfaces;
• cooling the molten molding material until it hardens into a solid single piece second body comprising a second external surface, the second external surface transitioning to second side walls and cooperating with the single piece first body to define a cavity suitable for carrying operational components of the portable computing device, wherein the direct bonding of the single piece second body to the single piece first body creates an overall external surface of the housing from the first and second external surfaces and the first and second sidewalls that is tactilely seamless.

A housing of a portable electronic device, comprising:

• a single piece first body formed of a first material and comprising a first external surface transitioning to first side walls having a first set of bonding surfaces;
• and
• a single piece second body formed of a second material and comprising a second external surface having first edges that define a first opening, the second external surface transitioning to second side walls, the housing formed by directly bonding the single piece second body in a non-solid form to the first set of bonding surfaces that is subsequently hardened into a solid form to create the single piece second body that in cooperation with the first body defines a cavity suitable for carrying operational components of the portable electronic device, wherein directly bonding the single piece second body to the single piece first body creates an overall external surface of the housing from the first and second external surfaces and the first and second sidewalls that is tactilely seamless.