Converting existing products or parts from metal to plastic reduces the weight and cost of manufacturing. Kaysun explains how the design flexibility of injection molding can be used to replace multiple metal parts with just one.

  • Mold Design & Tooling for Injection Molding - Featured in Product Design & Development
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The precision and complexity involved in injection molding is known to many manufacturers. Kaysun’s step-by-step explanation of designing the mold and its various components, known as tooling, highlights the company’s expertise.

Scientific molding eliminates the trial-and-error phase of injection molding by using specific data and analysis to develop a controlled, repeatable manufacturing process. Kaysun applies this technique across all of its parts manufacturing, with different specialists focusing on one area.

Smith’s Medical chose to partner with Kaysun Corporation to create its new, highly advanced SPECTRO2 pulse oximeter, basing the decision on Kaysun’s expertise in injection molding and experience with similar products. Smiths and Kaysun worked alongside each other to design, develop and test each prototype to ensure its strength, durability and accuracy. The result of the partnership is three precision-made pulse oximeters.

Kaysun Corp.’s president and CEO Ben Harrison discusses how replacing metal parts with plastic in soldier gear can reduce the weight and provide greater durability in the gear. With lighter packs, soldiers can move quicker and experience less fatigue, while trusting that their gear will hold up.

New materials in manufacturing are more durable, greener, and provide a greater number of advanced features for many industries, including electronics and medical. Kaysun recently helped design a new handheld device for a medical OEM, tasked with selecting only medical-grade materials that were chemical and flame resistant, had high impact strength, and could withstand cleaning agents used in medical environments.

Rockwell Collins, worldwide supplier of communications and aviation electronics, selected Kaysun Corporation as the winner of the Plastic Supplier of the Year and Lean Capstone awards for the second consecutive year. Kaysun’s contribution to Rockwell Collins with the Defense Advanced Global Positioning System demonstrated the injection molding company’s expertise in continually designing and creating highly precise injected molded components.

In only 12 weeks, Kaysun managed to consolidate the manufacturing lines of eight different medical patient monitoring devices into just one by embracing a lean manufacturing process. The production of the eight different patient monitoring devices was consolidated onto a single platform shared by three product families by cutting down on required parts, selecting proper materials, designing common casings that could be shared among different models, and reducing the variation in product design.

Modern Plastics Worldwide releases an annual list of the most Notable Processors, highlighting those who have contributed greatly to the advancement of the plastics and injection molding industry. Kaysun, in 2010, was named to the list due to its growth in the defense and medical industries. The injection molder has also aggressively pursued automation for welding, machining and potting to ensure high quality end products and output.

It is imperative that manufacturers and other companies looking to outsource properly evaluate any potential vendor. For manufacturers, Kaysun Corporation explains that ensuring both businesses are on the same page—and not only looking at profits—is an essential step of the process.

Cost cutting has affected American businesses for years, but the injection molding company saw great reductions in budget as well as less expensive competitors overseas. To battle this, Kaysun Corporation focused on emphasizing its design engineering. Concentrating on tight-tolerance injection, scientific molding, ceramic molding, and development and assembly for the medical industry in particular has proven to be a boon for the business.

Manitowoc, Wisconsin, had once been abandoned as a manufacturing site for cheaper locations abroad. A revival occurred as more companies began to reopen shop in the town, owing to its prime shipping location, access to expert workers, and proximity to large populations. Kaysun Corporation was one of such companies, discarding its overseas production business and focusing on high-quality plastic components for advanced technical and medical sectors and subsequently helping revive Manitowoc.

Kaysun Corporation, once a manufacturer of easily replaceable plastic toy parts and cookware, now focuses on creating high-tech items for the medical and military industries. This expertise ensures that their products cannot be replicated by cheaper, less experienced injection molding companies located in Asia. Kaysun’s emphasis on design and precise engineering has allowed the company to stay ahead of its less expensive competitors.

Rockwell Collins named Kaysun Corporation as the Lean Initiative and Plastic Supplier of the Year at its 2009 Annual Supplier Conference. This recognition was awarded based on Kaysun’s contribution to Rockwell Collins’ Defense Advanced Global Positioning System Receivers, with the injection molder’s focus on tight tolerance molding, lean manufacturing principles, cycle times, and costs.

 

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