A method of manufacturing a manifold assembly (22) in accordance with specifications required by a mold is provided. The method includes selecting a manifold (22) from a predetermined set of manifolds (22) and sub-manifolds (24) selected from a predetermined set of sub-manifolds (24). Both the manifolds (22) and the sub-manifolds (24) are at least partially manufactured to define first and second portions of the melt channels (28). Injection nozzles (26) are also selected for each sub-manifold (24), defining third portions of the melt channels (28). The manifold (22), the at least one sub-manifold (24) and the injection nozzles (26) are arranged and assembled together so that the first portions, the second portions and the third portions of the melt channels (28) cooperatively define the melt channels (28) operable to direct a melt material to gates located in the mold. The invention further includes a manifold assembly manufactured using the methods described herein.