Making the Right Choice in Materials

Posted by Kaysun Corporation on Aug 12, 2015 2:25:09 PM

What You Need to Know About Materials in Complex Injection Molding

With the freedom to create new features – and cost-effectively achieve process efficiencies – it’s evident why many design engineers lean toward parts and products that require complex injection molding.

What isn’t always clear, however, is what goes into it. That’s probably why it’s called “complex” injection molding, which involves more than a few considerations especially at the beginning of the process. Among them is the material used to make the actual mold, in addition to the plastic materials for the part. Here are pointers to keep in mind when working through it with a molder.

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Controlling Tight Tolerances for Injection Molded Parts

Posted by Kaysun Corporation on Aug 4, 2015 4:35:00 PM

Get Control of Tight Tolerances in the Design Phase and Come out Ahead

Here are three things design engineers fully understand:

  1. Design has almost everything to do with the success of product or part performance.
  2. The importance of design is magnified considerably with tight tolerances.
  3. If something goes wrong, check to see if the design is the root cause.

No pressure right? Wrong. There is a lot riding on the designer when developing complex plastic parts and products with tight tolerances, especially when they’re used in critical applications like medicine, auto manufacturing, and military among many others. Here’s why getting control of it in the design phase is a good thing, along with advice that should help take some of the pressure off.

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Topics: Overmolding

What Is Overmolding and Why Is It a Good Choice?

Posted by Kaysun Corporation on Jul 21, 2015 12:00:03 PM

Thinking Overmolding? Here's Why It's a Good Decision

If you’re contemplating whether to choose overmolding for your next product or part but aren’t 100 percent sure, it never hurts to think and then rethink. But to remove any shadow of doubt, here’s why overmolding will only continue to grow in popularity - and why it’s a solid choice.

What is overmolding again?

Overmolding is a unique injection molding process that results in a seamless combination of multiple materials into a single part or product. It typically includes a rigid, plastic-base component that is overlain by a thin, pliable, rubber-like thermoplastic elastomer (TPE) exterior layer or other materials. Two types of overmolding techniques used to combine the TPE layer and plastic substrate are single-shot (insert molding) and two-shot (multiple-shot molding).

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Five Key Considerations When Comparing Tooling Quotes

Posted by Kaysun Corporation on Jun 19, 2015 11:04:30 AM

Tooling Quotes: Five Tips to Help Get It Right

Almost nothing impacts the quality of the final injection molded product as the tool itself. That said, the pressure is on when it comes to securing a tooling quote. And here’s the trick: there is no trick. It’s all about information and reliance on those with expertise in the matter. It’s why we developed a whitepaper about it, which you can register for now. Meanwhile, here are five tips to help get it right.

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Topics: Tooling / Molds

The Key to Scientific Molding Is Engineers Who Specialize in It

Posted by Kaysun Corporation on May 19, 2015 9:54:00 AM

Much has been said about the ability of scientific molding to provide optimal control of the injection molding process – and in turn – help manufacturers of critical use-devices that contain precision-molded parts keep pace with competition and be the first to market. But what some wonder is what really makes scientific molding work in the first place. And the answer is the engineers who specialize in it.

When performed by molding personnel with thorough training and the proper certification, scientific molding virtually guarantees top quality by removing all guesswork from the injection molding process. The aim is to develop templates for repeatable production.

Here’s a look at the phases of scientific molding and the role that specialized engineers play to ensure success.

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Topics: Scientific Molding

The Future of Medical Injection Molding

Posted by Kaysun Corporation on Apr 23, 2015 2:53:22 PM

Advancements to polymers and injection molding technologies have contributed to widespread adoption of plastics in the medical industry. All segments of the medical industry have embraced the benefits of plastics. Low cost plastics have enabled the creation of disposable plastic instruments, syringes, gloves and gowns that in turn helped reduce the spread of infections within the hospital environment.

High performance polymers contribute to the longevity and friction-free movement found in current generation artificial joints. Handheld medical devices and instruments use plastics to reduce device weight, improve functionality or lower device cost. Plastics have replaced glass in a variety of laboratory consumables, improving lab safety while reducing consumable costs.

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Topics: Injection Molding

Benefits of Injection Molding Surgical Devices

Posted by Kaysun Corporation on Apr 3, 2015 2:32:20 PM

Medical grade polymers are quickly becoming the preferred material for a broad range of surgical devices. In certain applications, the robust mechanical properties of medical polymers allow complete removal of metal from the surgical device design.  In other instances, plastic and metal components can combine to create an enhanced product, with attributes that would not be possible in either an all-metal or an all-plastic device.

Incorporating plastic into surgical devices offers a number of benefits including reduced cost, improved ergonomics and increased functionality.  Below are some of the main reasons to consider injection molding for surgical devices:

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Injection Molding Expertise - Worth its Weight in Gold

Posted by Matt Fehrmann on Feb 16, 2015 12:05:00 PM

Injection Molding Expertise

It would be almost impossible to conceive of a world without plastic injection molded components. They turn up in just about everything we use, and most of us aren’t even aware of the amount of technical expertise that has been used to produce them. From the first glimmer of an idea to the production of the finished product, there is a chain of knowledge that has been incorporated into their design and manufacture. This process does not happen by chance; it is the culmination of many years of experience by highly trained and skilled designers and engineers.

Finding the right combination of injection molding experts under one roof is essential to successfully completing a production job. The molding company must be knowledgeable about the raw material, the variations in the molding machines, and the design of the mold. Every injection-molded component is different, and each has its own set of variables that the injection molding company must understand.

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Topics: Injection Molding

Plastics in the Automotive Industry

Posted by Matt Fehrmann on Feb 9, 2015 2:36:00 PM

A Solution to a Weighty Problem

More than ever before, automakers are under the gun to improve their car’s efficiency by increasing the fuel economy for all models. In 2012, President Obama finalized standards to increase fuel efficiency to nearly 55 mpg for both cars and light-duty trucks by 2025.

Although there are several ways to achieve this goal, reducing the car’s weight is one of the best – and easiest – ways to improve fuel economy without compromising other design and safety factors. And one of the heaviest components of any car is the powertrain. The powertrain’s weight contributes a disproportionate amount to the car’s overall mass, making the powertrain an area of focus for today’s aggressive automotive part injection molders.

The powertrain is one of a car's most complicated assemblies; it refers to the system of bearings, shafts and gears that transmit the engine’s power to the axle. Recently developed plastics materials can help reduce the number of parts needed to assemble these complex components while also reducing overall vehicle weight.

Plastic is Preferred 

Gone are the days when plastic was considered a cheap alternative to non-critical automotive components. Automotive engineers are combining plastics’ unique and variable properties to perfect designs and to improve their products’ efficiencies.

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Customer Service Can Make or Break a Company

Posted by Mary Stuiber on Sep 11, 2014 1:12:33 PM

Customer service is an integral part of every organization. Deals can be won or lost through the communication process. Honest communication, with the customer’s best interests always at the forefront—from the initial contact of the pre- sale to the support after the sale—is the cornerstone of good business practice.

With the technology we have today, customer service comes in many forms—face-to-face, phone, e-mail, Skype, the web, etc. And customer service isn’t limited to a call center or customer service personnel—any employee who interacts with a customer is a customer-service representative. It is ideal for account executives or project personnel to meet with customers face to face throughout the year, with frequency determined by customer preferences. It is important to stay connected on a regular basis to make sure you understand their needs, desires, and concerns (which can shift quickly, depending on the project or the market). Whether it is daily, weekly, or monthly dialogue, everyone needs to stay in the loop.

Excellent customer service is essential for:

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Topics: General Manufacturing

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