Abstract: An injection mold for manufacturing an injection molded polymer casing includes five separate mold portions cooperatively delimiting a casing’s volume. A base mold portion has an annularly shaped base cavity surface, a primer retention feature core extending from the base cavity surface, and a flash hole core extending from the primer retention feature core. A first transverse mold portion has a first half cavity surface configured to form a first half of the outside cylindrical surface of the casing. A second transverse mold portion has a second half cavity surface configured to form a second half of the outside cylindrical surface of the casing. A core pin mold portion has a frustoconical core configured for forming the inside cylindrical surface of the casing. A sleeve ejector mold portion forms the open-end surface of the casing and has a through hole for the core pin mold portion to be disposed through.

Abstract: A method of manufacturing a casing for an ammunition cartridge includes injection molding a first polymer forming a first part of the casing. The first part is cylindrically shaped along a longitudinal axis extending from a projectile end opposite a stepped end. The stepped end forms a first end of a mechanical connection. A portion of the injection mold is removed and an additional injection mold is disposed about the stepped end of the first end of the first part and a second polymer injected forms a second part of the casing. The second part includes a second stepped end forming a second end of the mechanical connection. The first and second end are mechanically locked together preventing a separation of the first part from the second part. A thermal swagging tool forms a conical tapered region along the projectile end of the first part.

Abstract: A method of manufacturing a casing for an ammunition cartridge includes injection molding a first polymer forming a first part of the casing. The first part is cylindrically shaped along a longitudinal axis extending from a projectile end opposite a stepped end. The stepped end forms a first end of a mechanical connection. A portion of the injection mold is removed and an additional injection mold is disposed about the stepped end of the first end of the first part and a second polymer injected forms a second part of the casing. The second part includes a second stepped end forming a second end of the mechanical connection. The first and second end are mechanically locked together preventing a separation of the first part from the second part. A thermal swagging tool forms a conical tapered region along the projectile end of the first part.

Abstract: A method of manufacturing a casing for an ammunition cartridge includes injection molding a polymer forming the casing using an injection mold. The casing is cylindrically shaped along a longitudinal axis extending from a base to a distal end with a blind hole formed therein. The blind hole has a primer retention feature disposed at the base and leads into a flash hole. An insulator and/or reflector is placed around at least a portion of the casing separating the base from the neck. A heater directly heats the neck of the casing while not directly heating the base. A stretch rod is inserted into the blind hole stretching the neck. The casing is inserted into a blow mold and pressurized causing the neck of the casing to be blow molded. At least a portion of the distal end of the casing is removed.