Patent ID: 8349240

Claim:
A molding system for producing a vehicle bumper fascia having a hidden parting line in a wheel flange area thereof, said system comprising: a bumper fascia injection mold, said mold including a core mold half with a primary mold core and a cavity mold half with a part cavity having a wheel arch flange undercut, each mold half adapted for mounting within an injection molding machine, said mold further comprising: cooperating pairs of movable secondary cores located on opposite ends of said primary mold core, said secondary core pairs each including an upper core and a lower core, a straight lifter connected to said upper core and an angled lifter connected to said lower core of each core pair, and an ejector plate coupled to said straight lifters and said angled lifters such that forward movement of said ejector plate will cause a forward movement of said upper secondary cores and a combined forward and inward movement of said lower secondary cores so that a wheel flange portion of a molded bumper fascia will clear said lower secondary mold cores upon mold opening, said bumper fascia remaining in said mold cavity due to said undercut therein; and a robotic part removal device including an extendable arm and an end effector coupled to said extendable arm, said end effector adapted to grip a molded bumper fascia while said bumper fascia resides in said mold cavity, to temporarily inwardly deform at least the wheel flange portions of the bumper fascia, and to retain the bumper fascia in such a deformed position at least until said wheel flange portions thereof clear said undercut in said mold cavity during removal by said robotic part removal device.