Patent ID: 7862324

Claim:
A system for forming solid ink sticks, the system comprising: at least one flexible molding tool having a vessel with a sidewall defining a cavity for receiving molten phase change ink material, the cavity defining at least a portion of an ink stick shape, the flexible molding tool being of a flexible, temperature resistant material to enable the sidewall to facilitate release of an at least partially solidified ink stick from the cavity; a molten phase change ink dispenser for introducing molten phase change ink material into the at least one cavity of the at least one flexible molding tool; a lid partially comprised of a flexible, temperature resistant material having an overflow passage and a receiving area, the lid being configured to enclose the cavity filled with molten phase change ink material and the overflow passage being configured to distend to enable a portion of the molten phase change material to flow through the overflow passage and solidify in the receiving area, the receiving area being recessed with respect to an upper surface of the lid and positioned on the lid to enable the solidified molten phase change ink material in the receiving area to capture a portion of the lid between the solidified molten phase change ink in the receiving area and solidified phase change ink in the cavity to couple the lid to the solidified phase change ink material in the cavity; and an ink stick extractor configured to grip the lid and withdraw the partially solidified ink stick from the cavity.