Abstract: A mold assembly, for an overhead console button carrier having a unitary body, includes a cavity side and a core side. The core side includes at least one zero draft core insert, a first buried retractor mechanism and a first slide mechanism.

Abstract: A method of forming a molding tool includes performing a computer aided engineering (CAE) analysis on a molding tool design. The CAE analysis predicts flow of injection molded material and a location of gas entrapment within a molding recess of the molding tool design. At least one venting design constraint is applied to the molding tool design as a function of the gas entrapment location. Also, a biomimetic shaped passageway for venting gas away from the gas entrapment location is selected from a plurality of biomimetic shaped passageways. A computational fluid dynamic (CFD) CAE analysis of the molding tool design with the selected biomimetic shaped passageway is performed and modifications of the selected biomimetic shaped passageway are CFD CAE analyzed until a final biomimetic shaped passageway is determined and a molding tool with the final biomimetic shaped passageway is formed.

Abstract: A center console for a vehicle includes a bin having a sidewall that defines an inner cavity. The sidewall has an interior surface and an exterior surface. A lid is rotatably coupled to the bin. The lid is operable between a lowered position enclosing the inner cavity and a raised position. The lid includes a body having a bottom surface. A support member is disposed on the bottom surface of the body. The support member includes a protrusion and a bumper. The protrusion and the bumper are coupled together via a connector.

Abstract: A mold assembly, for an overhead console button carrier having a unitary body, includes a cavity side and a core side. The core side includes at least one zero draft core insert, a first buried retractor mechanism and a first slide mechanism.

Abstract: A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Abstract: An overhead console button carrier has a unitary body. That unitary body includes a first light collimator, a second light collimator, a first intrusion sensor bracket, a second intrusion sensor bracket, a third intrusion sensor bracket and a plurality of button guides. A method and mold assembly for making the overhead console button carrier is also provided.

Abstract: A center console for a vehicle includes a bin having a sidewall that defines an inner cavity. The sidewall has an interior surface and an exterior surface. A lid is rotatably coupled to the bin. The lid is operable between a lowered position enclosing the inner cavity and a raised position. The lid includes a body having a bottom surface. A support member is disposed on the bottom surface of the body. The support member includes a protrusion and a bumper. The protrusion and the bumper are coupled together via a connector.

Abstract: A method of forming a molding tool includes performing a computer aided engineering (CAE) analysis on a molding tool design. The CAE analysis predicts flow of injection molded material and a location of gas entrapment within a molding recess of the molding tool design. At least one venting design constraint is applied to the molding tool design as a function of the gas entrapment location. Also, a biomimetic shaped passageway for venting gas away from the gas entrapment location is selected from a plurality of biomimetic shaped passageways. A computational fluid dynamic (CFD) CAE analysis of the molding tool design with the selected biomimetic shaped passageway is performed and modifications of the selected biomimetic shaped passageway are CFD CAE analyzed until a final biomimetic shaped passageway is determined and a molding tool with the final biomimetic shaped passageway is formed.

Abstract: An exemplary lamp assembly includes a lens, a base, and a textured surface between an outwardly facing surface of the lens and an outwardly facing surface of the base. An exemplary lamp molding method includes injecting a first material into a mold cavity to form a lens, and injecting a second material against a textured surface of the lens within the mold cavity to form a base.

Abstract: A headrest support assembly is provided that comprises a support member flexible between neutral and loaded states and having first and second ends with a channel extending therebetween. A cable is slidably received in the channel between first and second positions. The cable has first and second ends, and the cable moves from the first position to the second position when the support member moves from the neutral state to the loaded state.

Abstract: A headrest support assembly is provided that comprises a support member flexible between neutral and loaded states and having first and second ends with a channel extending therebetween. A cable is slidably received in the channel between first and second positions. The cable has first and second ends, and the cable moves from the first position to the second position when the support member moves from the neutral state to the loaded state.

Abstract: An overhead console button carrier has a unitary body. That unitary body includes a first light collimator, a second light collimator, a first intrusion sensor bracket, a second intrusion sensor bracket, a third intrusion sensor bracket and a plurality of button guides. A method and mold assembly for making the overhead console button carrier is also provided.

Abstract: A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Abstract: An exemplary lamp assembly includes a lens, a base, and a textured surface between an outwardly facing surface of the lens and an outwardly facing surface of the base. An exemplary lamp molding method includes injecting a first material into a mold cavity to form a lens, and injecting a second material against a textured surface of the lens within the mold cavity to form a base.

Abstract: An injection molding tool for molded-in-color injection molding is disclosed. The tool includes a first mold half that includes a mold cavity, a second molding half that includes a molding core, an ejector pin fluidly associated with the first mold half, and a gas removal vacuum system fluidly associated with the ejector pin. The first mold half and the second mold half meet at a parting line that is free of vents. In operation, the two halves are brought together, defining a mold cavity therebetween. The gas removal vacuum system is activated to remove any air that is trapped between the two halves. Once the trapped air has been removed, an article-forming, polymerizable resin is injected into the mold cavity. The gas removal vacuum system is again operated to remove gas generated by the polymerizable resin during the injection process.