Method for manufacturing a plastic speaker grill for wireless speaker assembly

A method for manufacturing a plastic speaker grill comprising the steps of:

• providing a first mold member and a second mold member collectively defining a cavity, the first mold member having a plurality of spaced mold pins extending into the cavity wherein distal ends of the pins are spaced from the second mold member;
• injecting molten plastic into the cavity and around the plurality of spaced mold pins to form a base member, the base member having a first side and an opposing second side and defining a thickness therebetween, the base member having a plurality of spaced blind holes wherein the first side is in communication with the plurality of blind holes and the second side defines a surface that is generally uniform and uninterrupted;
• removing the base member from the mold members;
• cutting the base member proximate the second side to remove a portion of the base member and define a grill member, wherein the removed portion of the base member exposes the blind holes to define apertures that extend completely through the grill member;
• and
• deburring the grill member to remove unwanted remnants of plastic material.