Abstract: A molding process is disclosed in which an extruded column of plastic is introduced into a mold cavity having a predetermined surface profile. A region of negative air pressure is created inside the mold cavity, exterior to the extruded column. The negative air pressure is applied to the exterior of the extruded column to draw the extruded column into contact with the entire surface profile of the mold cavity, to produce a molded article. The invention can also include a step of co-extruding multiple types of plastic resulting in an extruded column having multiple layers, to produce a molded article having multiple layers. The present method also includes a step of internally inserting a component into the extruded column at a predetermined position so that it will end up at a predetermined position of the molded article after the molding process.

Abstract: A molding process and apparatus are disclosed herewith including extruding a polymer from at least one nozzle into a mold cavity, and displacing at least one of the nozzle and the mold cavity during the step of extruding to deposit at least a portion of a layer of polymer into the mold cavity, and subsequently enclosing the mold cavity with a mating mold section to produce a molded part.

Abstract: A molding process is disclosed in which an extruded column of plastic is introduced into a mold cavity having a predetermined surface profile. A region of negative air pressure is created inside the mold cavity, exterior to the extruded column. The negative air pressure is applied to the exterior of the extruded column to draw the extruded column into contact with the entire surface profile of the mold cavity, to produce a molded article. The invention can also include a step of co-extruding multiple types of plastic resulting in an extruded column having multiple layers, to produce a molded article having multiple layers. The present method also includes a step of internally inserting a component into the extruded column at a predetermined position so that it will end up at a predetermined position of the molded article after the molding process.