Patent ID: 8840825

Claim:
A method of manufacturing an apparatus for cushioning and protecting body parts of a human or animal comprising a blend of dual durometer resilient flexible materials with a plurality of degrees of hardness to personalize the properties of comfort, proper fit, structure, and protection; wherein said resilient flexible materials comprise thermoplastic, thermoset, casting, curing, epoxy, or resin materials; and wherein a soft part is customizable, comprising the steps of: creating a mold with multiple cavities outlining a body part to be protected; utilizing a rotary, two shot, tool indexing means wherein the molding is either loaded by hand or manual means or loaded by automatic or robotic means; loading the mold in at least two intervals with similar or dissimilar thermoplastic resins; loading the first shot of a thermoplastic resin into a first cavity in the mold while the mold is closed; rotating the mold either by hand or automatically, and loading a second shot of a similar or different thermoplastic resin into a second cavity while the mold remains closed; bonding the first and second shot thermoplastic resins mechanically and/or chemically to one another.