Molding Apparatus

1 . A molding apparatus comprising:

a frame;

a mold assembly having a first mold and a second mold, the second mold coupled to the frame;

a transmission assembly coupled to the frame and to the first mold, the transmission assembly including a rotatable gear and a shaft, the gear being configured such that rotation of the gear moves the shaft and the first mold;

a motor coupled to the transmission assembly, the motor being configured to turn the gear to move the first mold relative to the second mold; and

a pneumatic actuator coupled to the transmission assembly, the pneumatic actuator being configured to turn the gear to increase clamping pressure between the first mold and the second mold.

2 . The molding apparatus of claim 1 , wherein the gear comprises outer teeth and wherein the outer teeth are engaged by the motor and the pneumatic actuator.

3 . The molding apparatus of claim 2 , wherein the gear comprises a central thread, wherein the shaft is a threaded shaft, and wherein the central thread engages the threaded shaft.

4 . The molding apparatus of claim 1 , additionally comprising one or more guides configured to maintain alignment of the first mold and the second mold during relative movement therebetween.

5 . The molding apparatus of claim 4 , wherein at least one guide comprises a shaft that extends through an aperture in the first mold.

6 . The molding apparatus of claim 1 , further comprising at least one counterbalance assembly that counterbalances the weight of the first mold.

7 . The molding apparatus of claim 6 , wherein the at least one counterbalance assembly comprises at least one piston operatively connected between the first mold and the frame, the piston being located within a chamber, wherein downward movement of the first mold moves the piston within the chamber, creating a change in pressure in the chamber such that the changed pressure provides an upward force on the piston and the first mold.

8 . The molding apparatus of claim 1 , further comprising a controller, wherein the controller is configured to control pressure of molding material injected into the mold assembly to between 3 psi and 15 psi of a predetermined molding material pressure.

9 . The molding apparatus of claim 8 , wherein the controller is configured to control pressure of molding material injected into the mold assembly to between 3 psi and 8 psi of a predetermined molding material pressure.

10 . The molding apparatus of claim 1 , further comprising a measurement mechanism configured to measure the volume of molding material injected into the mold assembly.

11 . The molding apparatus of claim 1 , further comprising a heated reservoir configured to melt molding material.

12 . The molding apparatus of claim 11 , wherein the reservoir includes baffles defining channels therebetween.

13 . The molding apparatus of claim 12 , wherein the baffles are configured to provide a predetermined maximum distance to a heated surface for molding material located in the reservoir.

14 . The molding apparatus of claim 13 , wherein the predetermined maximum distance is 17 millimeters.

15 . A method for molding using a mold apparatus comprising a first mold and a second mold, the first mold being moveable relative to the second mold, the method comprising:

operating a motor to bring first and second molds into and out of interface engagement with each other;

operating a pneumatic actuator to apply clamping pressure between the first mold and the second mold;

monitoring the pressure of the molding material in the mold assembly; and

monitoring the volume of molding material injected into the mold assembly.

16 . The method of claim 15 , wherein the motor operates on a first gear to move the first mold and wherein the pneumatic actuator operates on the first gear to apply clamping pressure between the first mold and the second mold.

17 . The method of claim 15 , further comprising controlling the pressure of the molding material in the mold assembly to between to between 3 psi and 15 psi of a predetermined molding material pressure.