A mold assembly for forming a multi-shot molded part includes a mold
system defining a mold cavity, and a retracting member disposed in the
mold system selectively movable between extended and retracted positions
in the mold cavity. A first molding material is injected in the mold
cavity when the mold system is in a configuration with the retracting
member in the extended position, forming a first portion of a molded part
including a thin wall portion. A second molding material is injected in
the mold cavity when the mold system is in another configuration with the
retracting member in the retracted position, forming a second portion of
the molded part and providing open cavity portions adjacent both surfaces
of the thin wall portion. The second material penetrates the thin wall
portion, filling the open cavity portions and forming a connection
between the first and second portions of the molded part.