Abstract: A method of forming a hybrid injection molded component in which a metal core is formed and a chemically inert outer shell is formed over the metal core. The metal core material is thixotropically injected into a first mold, cooled, and removed from the first mold. The metal core is then inserted into a second mold and held in place with pin locators. Thermoplastic material is injected into a gap between the metal core and the second mold so as to form the outer shell. The pin locators are retracted and the thermoplastic material is allowed to fill in the spaces previously occupied by the pin locators.