A multiple material carrier plate assembly molding method using insertable, removable, replaceable non-ferrous pre-molded inserts each having at least one mold cavity, removably inserted into two removable carrier plates for use in precision molding, the method comprising:
- a first step of fabricating at least one pair of removable carrier plates of a ferrous material adapted for long-term use in a production precision molding machine, each of the pair of carrier plates having a mating matrix of insert receptacles arranged in a given pattern and precision position for precision alignment of the mating pair of carrier plates, the at least one pair of carrier plates having at least one pair of mating insert receptacles, having one of the mating pair of insert receptacles in each carrier plate, the pair of mating insert receptacles mutually aligning when the carrier plates are moved together in a molding process;
- a second step of pre-molding at least one pair of insertable, removable, replaceable non-ferrous pre-molded inserts each having at least one mold cavity, each of the pre-molded inserts comprising outer edge configurations adapted for aligning with and engaging a mating insert receptacle in a removable carrier plate for use in precision molding, each of the mating pair of pre-molded inserts further comprising a plurality of pairs of mating alignment elements for automatically lining up the at least one pair of mating pre-molded inserts precisely during the mating of the at least one pair of pre-molded inserts in the molding process, the mating pre-molded inserts fabricated of a nonferrous pre-molded material adapted for withstanding operating temperatures and compression pressure required for a production precision molding process;
- a third step of inserting at least one mating pair of the pre-molded inserts into a mating pair of insert receptacles in the pair of mating carrier plates, each of the pre-molded inserts removably inserted in each of the mating insert receptacles in a floating fit configuration allowing each of the pre-molded inserts to float in all three axis within the insert receptacle allowing for self-aligning between the at least one mating pair of pre-molded inserts in the pair of removable carrier plates, thereby forming a multiple material assembly with mating pairs of three axis replaceable pre-molded insert floating molds attached to at pair of removable carrier plates for use in production precision molding;
- a fourth step of installing the pair of mating removable plates in a production precision molding machine, the mating pair of removable carrier plates comprising a top carrier plate positioned horizontally above and parallel to a mating bottom carrier plate in the production precision molding apparatus;
- the at least one mating pair of non-ferrous pre-molded inserts comprising at least one top pre-molded insert adapted to be inserted in the top carrier plate and at least one mating bottom pre-molded insert adapted to be inserted in the bottom carrier plate, the top pre-molded insert comprising a bottom mating contact face facing downwardly for interfacing with a mating bottom pre-molded insert mating contact face facing upwardly in the bottom mating carrier plate, the mating contact faces each comprising a flat surface portion having a plurality of mating alignment elements adapted for automatic precision alignment of the mating pair of pre-molded inserts, each mating insert face having a mating mold cavity recessed in the flat surface portion communicating with the other mold cavity on the other mating face, the at least one top pre-molded insert further comprising a top surface opposite the bottom mating contact face, the top surface having a recessed area comprising a pot connected by at least one runner and at least one cavity gate communicating with top and bottom mold cavities for injecting liquefied synthetic material therein during a production precision molding process;
- a fifth step of installing on the top surface of each of the top pre-molded inserts an injector structure comprising a plunger and pot bushing structure adapted for communicating with the pot, the structure comprising a plunger rod in a pot bushing adapted for transmitting liquefied synthetic material to the assembly, the plunger comprising a plunger tip at a lower end of the plunger configured to inject the liquefied synthetic material into the pot and mating mold cavities, and a mating pot bushing structure configured to receive the liquefied synthetic material for transmitting the liquefied synthetic material to the pot on each top pre-molded insert, the plunger tip further comprising a plunger core pin adapted for communicating with the pot bushing structure, and the plunger tip further comprising a structure having a cavity adapted for receiving the liquefied synthetic material to occupy the cavity and solidify therein, the synthetic material within the cavity encasing the core pin so that the tip is adapted to extract the solidified material from the pot, the runner, and the gate of the pre-molded insert without an ejector system;
- the pot bushing further comprising an angled surface and ledge within a face of the bushing adapted for a stripping action of the core pin and separation from the cavity structure so that retraction of the plunger separates the solidified material from the plunger face for automatic removal of surplus injected material after each molding cycle, thereby eliminating any need for an ejector system and eliminating any need for a runner system;
- a sixth step of using the multiple material assembly carrier plates in a precision molding device for precision molding;
- thereby performing a multiple material carrier plate assembly molding method using insertable, removable, replaceable non-ferrous pre-molded inserts each having at least one mold cavity, removably inserted into two removable carrier plates for use in precision molding.