Scientific Molding Is in High Demand

Posted by Kaysun Corporation on Oct 22, 2012 2:00:00 PM

blank.pngIf you want top quality, minimal defects, fast production, and lower cost over the life of the product line, there’s no question that scientific molding is the way to go. It is also the way to increase market share, because your reputation for high quality and performance will grow and get the attention of new prospective buyers.

Scientific molding results inthe best designed and controlled manufacturing process for your product—especially if it is a high-performance, critical-tolerance part.

Injection molding is a complex process with plenty of variables that need to be carefully monitored and controlled. Scientific molding achieves this by using detailed material science and precise measurement to completely understand, down to the molecular level, what’s happening during each stage of the injection molding process. This will eliminate annoying issues with things like:

  • Resin optimization

  • Evaluating and blending color concentrates

  • Molding and tooling design

  • Process and material variations

  • Not meeting specs

  • Re-validation

  • Meeting regulatory requirements

More companies are asking Kaysun about scientific molding for their critical-use, complex parts and devices, or precision-molded plastic parts, because the standard molding procedures they have used in the past simply cannot meet their current product specifications.

By fully understanding how all the many material and process parameters interact together at all times during production, our scientific engineers maintain high precision across multiple production runs. Sophisticated software and sensors monitor each phase of the manufacturing process, allowing our team to know what’s happening with the material inside the mold at all times; they know how small changes in pressure, temperature, viscosity, flow rate, material moisture rate, fill time, and cooling rate impact quality of the final product and can correct any process variations with seconds.

Because all the data is recorded, we can easily replicate the manufacturing process as needed—even when production is transferred from one machine to another—saving a tremendous amount of setup time. This is also essential for validating the process and meeting any regulatory requirements.

By understanding each phase of product development, and all aspects of material behavior, Kaysun’s scientific molding engineers design the most efficient process possible for your product, which minimizes or even eliminates scrap—saving money on material costs and speeding up throughput because “peak production” is maintained through the entire process.