Abstract: The present invention relates to a process for integrally molding an assembly, having parts in a die lock situation, in a single molding step. The molding process of the present invention has the steps of providing a composite component with a predefined contour, molding a core fuel rail integrated with the composite component, connecting the core fuel rail to a main core structure, overmolding the combined core fuel rail and main core structure to form a finished assembly, removing and melting out the combined core fuel rail and main core structure and extracting the composite component to provide the finished assembly with a substantially accurate finish. The present invention also relates to a manifold with integrally formed core fuel rails. The core fuel rails and injector pockets are molded together with the main manifold body in a single step although the injector pockets are in a die lock situation relative to the main manifold body.