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Al Timm

Recent Posts

Plastic Regrind Saves on Money and Materials

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Chemical Resistant Resins for Medical Applications

Critical-use medical devices are essential in the performance of important and often life-saving tasks. As such, they often boast complicated designs and functionality that require the expertise of a complex injection molder to produce. However, that’s only part of the equation.

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8 Steps to Optimizing the Injection Molding Process

The complexities of engineering a plastic part or product for use in a critical-use application must translate to moldability. If a molder is inexperienced in mold design and process optimization, there’s a good bet they won’t be familiar with methodologies essential for creating a highly efficient production process such as scientific molding and, more specifically Design of Experiments (DOE) within scientific molding. This article discusses key steps tool and process engineers take to ensure consistent and repeatable manufacturability of flawless molded parts.

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Prototype Tooling—What Option Is Best for You?

There are several options for prototyping your designs—the one you choose really depends on what you expect to accomplish with the prototype. For example, is the prototype just for show or will it be subjected to some testing? The most common prototyping options are SLA/SLS, urethane cast, soft tooling, and hard tooling. But which is right for your component? Read on to discover the advantages and disadvantages of each.

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Preventing Common Manufacturing Defects in Medical Applications

Manufacturers of medical devices and other medical applications often turn to a complex injection molder for help correcting defects in their engineered plastic components. At Kaysun, we actively seek to prevent defects before they even occur by using a design for manufacturability (DfM) approach that incorporates a comprehensive mold flow analysis and extensive plastics engineering experience to identify any potential issues in the design phase and determine the best strategy to produce defect-free parts.

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Top 5 Injection Molding Defects in Medical Applications

Complex injection molders entrusted with producing plastic components for medical and other critical-use applications assume a high degree of responsibility to ensure the device performs properly, without fail in sometimes life-endangering situations.

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Tonnage Calculation's Impact on Cost Control

Injection molding is a complex, dynamic system with multiple, interacting factors—all of which impact performance, cost, and quality. One of these factors is the tonnage calculation, also known as the clamping force of the injection molding machine.

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Overmolding: Key Considerations When Selecting Materials and Molders

Overmolding is a value-added injection molding method for improving plastic and metal substrate performance and aesthetics. While seemingly simple, the process has a number of underlying complexities which must be carefully considered to ensure your overmolding project meets all goals and expectations.

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What is Design of Experiments in Scientific Molding?

Each new injection molding project has three inherent goals: performance for the customer; production efficiency for the manufacturer; and reliability for the end user. These goals are reasonable. The challenge lies in accomplishing all three within a desired timeframe and budget. To do so, plastics engineers at complex injection molders turn to Design of Experiments (DOE) to identify flaws that would otherwise derail project success.

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What is Design for Manufacturability in Injection Molding?

In broadest terms, Design for Manufacturability (DfM) — also known as Design for Manufacturing — is the process of consciously and proactively designing products to optimize all facets of manufacturing, including injection molding. DfM simultaneously helps ensure cost and time efficiencies, superior quality, regulatory compliance and end user satisfaction. Since manufacturing processes vary, there are set guidelines for DfM practices that define tolerances, rules and best practices.

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