System and method of sealing coil leads during encapsulation

A method of coil lead sealing during coil encapsulation, the method comprising steps of:

• positioning at least one lead of a coil into a tube having an inner diameter greater than an outer lead diameter so that a gap remains between the lead and tube;
• placing the coil into a mold having an injection opening;
• closing the mold so that an interior thereof remains open to an external environment surrounding the mold through the gap remaining between the lead and tube;
• and
• injecting liquid encapsulation material under pressure through the injection opening and into the closed mold interior so as to encapsulate the coil and flow from the mold interior through the gap and toward the external environment,
• wherein said injecting is conducted at an injection rate, encapsulation material temperature, external environmental temperature, mold temperature, and/or coil temperature causing the encapsulation material to solidify while flowing through the gap and before flowing out of a distal end of the gap into the external environment.