Patent ID: 7144537

Claim:
A method of injection molding multi-material parts, comprising the steps of: (a) injecting a first molten material into a portion of a plurality of first mold cavities interspersed alternately among a plurality of second mold cavities in a mold and solidifying the molten material; (b) opening the mold and retaining the solidified material on a plurality of mold cores; (c) moving the mold cores with the solidified material to the second mold cavities and closing the mold; (d) injecting a second molten material into a portion of the second mold cavities and solidifying the molten material such that the first and second materials together form the multi-material part; (e) opening the mold and ejecting the multi-material parts; (f) preventing injection of molten material into a cavity from which a core have been moved; and (g) wherein the injection of molten material is prevented by installing a dummy core into at least one of the mold cavities from which at least one of the mold cores has been moved, the dummy core interfacing with an injection nozzle in the cavity to prevent the nozzle from injecting molten material during an injection cycle.