Wright Medical Technology, Inc.

Brian L Norberg

Jeffrey G Marx

Bradley R Heckendorf

James J Cassidy

Ying Ko

Sacrificial inserts and molds for use in injection molding are disclosed. In one embodiment a sacrificial insert includes a water-insoluble insert which has a melting temperature greater than the injection molding melt temperature of the base material being molded. In another embodiment, a mold includes one or more of: a sacrificial insert configured to form interior features of the object; a sacrificial insert configured to form interior and exterior features of the object; and a combination of a sacrificial insert configured to form exterior features of the object and a tool configured to form interior features of the object. In another embodiment, a multi-shot injection molding process includes: providing a support base containing a tool; injecting a first material into the support base to form an integral tool and sacrificial insert; separating the tool from the sacrificial insert; retaining the sacrificial insert in the support base, or inserting the sacrificial insert into another support base optionally having a further sacrificial insert or tool; injecting a second material into the support base containing the sacrificial insert to form an integral sacrificial insert and molded object; and destructively disengaging the sacrificial insert from the molded object without substantially damaging the molded object. In another embodiment, a sacrificial insert is used to injection mold a metal or ceramic object.

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Durand, WI, United States of America

Brian L Norberg