Provided is a molding system for molding a thermoplastic article. The molding system comprises a first mold half and a second mold half. The first and second mold halves together define a plurality of molding cavities in a first closed position. The plurality of cavities serve to mold a corresponding plurality of article components in a first molding stage. Subsequent the first molding stage, the first mold half is displaceable relative to the second mold half to align the plurality of article components formed during the first molding stage. During a second molding stage, the first and second mold halves are closed to a second closed position, to engage and bond together the plurality of article components into a finished thermoplastic article.

Provided is a molding system for molding a thermoplastic article. The molding system comprises a first mold half and a second mold half. The first and second mold halves together define a plurality of molding cavities in a first closed position. The plurality of cavities serve to mold a corresponding plurality of article components in a first molding stage. Subsequent the first molding stage, the first mold half is displaceable relative to the second mold half to align the plurality of article components formed during the first molding stage. During a second molding stage, the first and second mold halves are closed to a second closed position, to engage and bond together the plurality of article components into a finished thermoplastic article.

What is presented is a mold support structure in a single dual injection molding machine for plastic part formation having at least two injection units. The mold support structure comprises at least one pair of platens located on opposite sides. Each pair of platens is separated by a plurality of reinforcement structures that provide support in the direction in which clamp and injection pressure is applied to the pair of platens during plastic part formation.

An injection molding apparatus and method of fabricating a molded part are provided. The apparatus may include a barrel, a nozzle enclosing an end of the barrel and defining an opening in fluid communication with an inside of the barrel, and an extrusion screw positioned at least partially inside the barrel and rotatable relative to the barrel. The extrusion screw may include a screw tip. Relative axial movement between the barrel and the extrusion screw may open or close the opening of the nozzle to permit or prevent, respectively, material flow through the opening of the nozzle. The method may include clamping a mold, opening a nozzle, rotating the extrusion screw to pump a molten material into the mold until the mold is filled, closing the nozzle, and unclamping the mold to release a molded part.

An injection molding apparatus and method of fabricating a molded part are provided. The apparatus may include a barrel, a nozzle enclosing an end of the barrel and defining an opening in fluid communication with an inside of the barrel, and an extrusion screw positioned at least partially inside the barrel and rotatable relative to the barrel. The extrusion screw may include a screw tip. Relative axial movement between the barrel and the extrusion screw may open or close the opening of the nozzle to permit or prevent, respectively, material flow through the opening of the nozzle. The method may include clamping a mold, opening a nozzle, rotating the extrusion screw to pump a molten material into the mold until the mold is filled, closing the nozzle, and unclamping the mold to release a molded part.

A reconfigurable melt delivery system is disclosed for use with a first injection unit and a second injection unit. The reconfigurable melt delivery system may include a first arm manifold configured to receive a moldable material from a second injection unit, an exchangeable second arm manifold in fluid communication with the first arm manifold that is configured to receive the moldable material from the first arm manifold and to transfer the moldable material to an outlet nozzle, and a repositionable and replaceable insert plate configured to be repositioned or replaced relative to remaining plates of the melt delivery system, wherein the outlet nozzle is secured within a mold facing surface of the insert plate and is radially offset from a central machine nozzle opening of the melt delivery system for delivering the moldable material to a corresponding offset mold gate of a two-material mold.

A reconfigurable melt delivery system is disclosed for use with a first injection unit and a second injection unit. The reconfigurable melt delivery system may include a first arm manifold configured to receive a moldable material from a second injection unit, an exchangeable second arm manifold in fluid communication with the first arm manifold that is configured to receive the moldable material from the first arm manifold and to transfer the moldable material to an outlet nozzle, and a repositionable and replaceable insert plate configured to be repositioned or replaced relative to remaining plates of the melt delivery system, wherein the outlet nozzle is secured within a mold facing surface of the insert plate and is radially offset from a central machine nozzle opening of the melt delivery system for delivering the moldable material to a corresponding offset mold gate of a two-material mold.

A modular barrel and screw assembly for use in injection molding including a barrel having a barrel body, a separate barrel injection portion and a separate barrel end cap, with the barrel end cap being removably connected to the barrel injection portion and the barrel injection portion being removably connected to the barrel body, and a screw assembly having a screw tip assembly removably connected to a screw portion, wherein an injection chamber having a shot volume is defined by the barrel injection portion, the barrel end cap and the screw tip assembly. The modular barrel and screw assembly enables servicing of the barrel injection portion, barrel end cap and/or screw tip assembly without requiring removal of the barrel body, and enables use of a plurality of alternative corresponding separate barrel injection portions, separate barrel end caps and tip assemblies that provide a plurality of different shot volumes.

A molding unit has a first molding station having a first mold having a first mold cavity, a second molding station having a second mold having a second mold cavity, a transfer unit having a support and at least a first core extending from the support. The transfer unit is arranged for moving the first core into a first molding position at the first molding station and into a second molding position at the second molding station. The first core extends into the first mold cavity when the first core is in the first molding position and into the second mold cavity when the first core is in the second molding position. A core actuation unit is arranged so that at least at the first molding station the first core is moved relative to the support from a first core position into a second core position when the first core is moved into the first molding position.

A molding unit has a first molding station having a first mold having a first mold cavity, a second molding station having a second mold having a second mold cavity, a transfer unit having a support and at least a first core extending from the support. The transfer unit is arranged for moving the first core into a first molding position at the first molding station and into a second molding position at the second molding station. The first core extends into the first mold cavity when the first core is in the first molding position and into the second mold cavity when the first core is in the second molding position. A core actuation unit is arranged so that at least at the first molding station the first core is moved relative to the support from a first core position into a second core position when the first core is moved into the first molding position.