Kaysun Blog

Worldwide, sales of electric vehicles rose by 73% in 2018 — a banner year by any measurement, but all the more remarkable given it followed sales growth of 86% in 2017. The sales figures are more than impressive; they reflect a shift in consumer demand for affordable, eco-friendly transportation options and the bellwether of change in the automotive industry.

An increased speed to market is a distinct competitive advantage, but making speed your first priority can jeopardize injection molding process efficiencies — and product performance.

Accelerating speed to market and upholding quality doesn’t need to be an "either or" proposition. Early in the design phase, seek out an injection molding partner that thinks and delivers beyond the standard injection molding process. If your ultimate goals include preventing costly rework, and eliminating defects and unanticipated product failure, look for an injection molder with expertise in mold filling analysis, scientific molding, and other time and cost saving process methodologies.

Recently, Kaysun earned MedAccred Plastics accreditation. Our commitment to excellence is well documented through other certifications including ISO 13485:2016 and IATF 16949:2016. However, the MedAccred designation puts Kaysun in an elite group of injection molders that can capably and confidently serve the medical industry — assuring medical OEMs of an unparalleled benchmark of production and quality standards.

Manufacturers tasked with making products that serve a wide range of functional and aesthetic purposes often turn to multi-material injection molding for solutions – more specifically, to insert molding and overmolding. Since the two processes bear some similarities they’re often thought of as interchangeable, but there are some key differences.

The complexities of engineering an injection molded plastic component or part for a complex application must translate to moldability. If a molder is inexperienced in tool design and process optimization, there’s a good chance 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. Let's take a look at the key steps that tool and process engineers take to ensure consistent and repeatable manufacturability of flawless molded parts.

There are several prototype tooling options for your designs — the one you choose really depends on what you expect to accomplish with the prototype. For example, will the prototype be subjected to testing? Does it need to be "dressed up" for presentation? Will it need to meet tight tolerance requirements?

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.

Manufacturers cannot afford to lose any time in getting their products to market. Advances in technology come rapidly, ratcheting up competition for market share. To ensure success, products must be designed and produced with ultimate precision and efficiency. That efficiency depends on eliminating production delays caused by inconsistencies in the manufacturing process.

When you approach a custom injection molder to produce complex plastic parts or components, determining if the product is suitable for a streamlined injection molding process is one of the first steps.

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 overlaid with a thin, pliable, rubber-like thermoplastic elastomer (TPE) exterior layer or other materials using either a single-shot (insert molding) or two-shot (multiple-shot molding) technique.