Benefits of Scientific Molding

By working with Kaysun throughout the manufacturing process, including tool building, our partners get the benefit of our experience and expertise in scientific injection molding. With engineers who specialize in each phase of the product development cycle, we provide expert guidance throughout the tool design and development process and the molding and manufacturing process.

These highly educated specialists adapt their skills to each unique situation. Within the scientific injection molding process, they identify which tests are relevant for each unique application. Then they analyze and interpret the data to determine just how to fine-tune the variables to yield a robust process that delivers defect-free parts with 100-percent consistency and repeatability.

A properly executed decoupled molding process creates a wider processing window, meaning fewer defects and higher efficiency. Effective analysis of the data gathered helps in correcting problems before they grow costly. The benefits are:

  • Assuring consistent and precise quality of parts
  • Lowering the cost per piece
  • Maximizing efficiency through time, materials, and costs saved

Properly managed decoupled molding prevents repeated non-conformance to dimensional requirements and minimizes any quality issues.

Why Partner with Kaysun for Scientific Molding?

Manufacturers of tight-tolerance, critical-use devices need to get their products to market quickly and successfully. You can count on Kaysun’s deeply experienced team for efficient and innovative solutions for all your manufacturing needs. We are committed to remaining the injection-molding thought leaders. Our engineers continuously build their expertise with ongoing training and certification, including Master Molder I and II , where participants become adept in decoupled molding processes and strategies.

You can’t cut corners on quality. Choose an injection-molding partner with the absolute expertise in scientific molding for the ultimate reliability and consistency for your critical-use products.

We have been achieving the improbable with plastics for more than 60 years, and we invite you to send your toughest engineering challenges our way.

Decoupled Molding

Decoupled molding has taken the old method from an art to an exact science.

That precise control comes from skilled analysis of intricate scientific testing. There are no assumptions or opinions involved, just data that specifically trained and certified engineers interpret to identify where to adjust the process for optimal parts and the most efficient injection molding cycle time.

Types of Decoupled Molding

Decoupled I (partially decoupled), where the mold is filled 100 percent on first-stage pressure, is marked by unbridled kinetic energy and a lack of control in the packing phase. It is an outdated method that is not used at Kaysun.

Decoupled II (fully decoupled molding) involves fully separating the fill and pack phases of the injection molding process for a controlled end. This prevents the pressure build-up of a too-rapid fill. The cavity fills quickly, but that stage is decoupled from the pack stage so the kinetic energy is spent before mold flash occurs. At the decoupling point, 95 to 99 percent of the mold cavity is filled, with the remainder to come in the controlled pack stage. The hold stage is also included in this second step.

Decoupled III (totally decoupled) further refines the process by separating it into three, rather than two, stages: fill, pack rate and hold. Fill is the same as in Decoupled II molding process, but the pack rate is done at low speed until pressure in the mold cavity reaches the desired level. The process-control point pivots to sensors within the mold that read where the plastic is, resulting in a much more controlled process. The kinetic energy is lowered more gradually than in II, and the pack rate is very precise. Decoupled III is more complex and requires special machines or modification of existing machines. Cavity-pressure transducers must be added to the molds and then interfaced electronically with the injection-molding machine as well as the E-dart monitoring system.