Patent ID: 8230575

Claim:
A method of fabricating an electrical assembly, comprising: providing a plurality of electrically conductive circuit elements; providing at least one circuit element comprising a board having a side surface and a plurality of conductive tracks disposed on the side surface of the board; securing at least one electrical component to at least a selected one of the conductive tracks; positioning at least a portion of the circuit element and the electrical component in a first mold cavity having a first shape; molding thermoplastic polymer material around the electrical component while it is in the first mold cavity to encapsulate the electrical component in a protective capsule of thermoplastic polymer material, the protective capsule having a first portion in contact with the conductive tracks and the board, the protective capsule having peripheral edge portions extending around at least a portion of the electrical component; positioning at least a portion of the circuit element and the electrical component in a second mold cavity having a second shape that is substantially different than the first shape; molding thermoplastic polymer material over at least a portion of the protective capsule.