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7 Ways Exceptional Engineering Improves Custom Injection Molding

Posted by Jenna Keib on Jul 28, 2021 9:46:17 AM
Jenna Keib

Exceptional engineeringThere’s no denying that pandemic-related, weather-influenced, and manmade disruptions have caused chaos within the plastics industry. For OEMs, finding injection molding solutions during these turbulent times is problematic. Finding knowledgeable molders to take on complicated design, engineering, injection molding, and other challenges that less skilled molders can’t handle is equally as difficult.

The latter is an ongoing frustration for OEMs. Oftentimes, the limitations of commodity molder aren’t revealed until plastic part defects evidence themselves. Or, perhaps the molder openly acknowledges inexperience with certain advanced skills and refuses the job. Either way, it puts the OEM in a precarious position.

Everything from engineering complex plastic parts through production requires confidence and capabilities that only experience can provide. That’s why Kaysun is the preferred custom injection molding partner for OEMs across industries

Applying Knowledge, Leveraging Technology

The Kaysun production line has state-of-the-art injection molding technologies, capable of producing sophisticated, high-quality plastic parts. But simply having the equipment doesn’t guarantee success.

Custom injection molding doesn’t start at the production line. It encompasses an entire process. In-house design, testing, manufacturing, and assembly capabilities underpin Kaysun quality.

These robust engineering support services also give our partners peace of mind. Simply put, there’s a greater likelihood that their most daunting design, engineering, injection molding, and related challenges will be solved:

  1. Design for Manufacturability (DfM): In broadest terms, Design for Manufacturability (DfM) — also known as Design for Manufacturing — is the process whereby specially trained engineers consciously and proactively design parts to optimize all facets of manufacturing, including injection molding. DfM aligns engineering and production in the initial design phase so potential problems can be identified and resolved before they result in costly rework.
  2. Part Design: Making customers’ “what if” possibilities realities is what Kaysun does best. Exploring the practicalities of prospective part design often leads to innovations that streamline processes and allow for quick decisions on advanced design, material selection, prototyping, molding and tool design, and production.
  3. Tool Building: Highly technical, tool building is often as complex as the part for which it is designed. Kaysun engineers rely on their in-depth knowledge and training about material behavior to guide tooling decisions that optimize production and control costs.
  4. Resin Selection Support: With 25,000+ engineering resins available, narrowing down thousands of options to a handful of suitable choices doesn’t happen by chance. Collaboration with a molder practiced in materials science and behaviors helps align resins with the function, environment, exposure risk, and performance expectations.
  5. Metal to Plastic Conversion: When left to experienced custom injection molders like Kaysun, metal to plastic conversion can be a powerful solution for decreasing part weight and lowering costs without sacrificing tight tolerances or performance. This commitment to quality is particularly attractive to OEMs that have encountered problems with other molding vendors that resulted in additional machining costs, recalls, and risk of potential litigation.
  6. Product Testing and Analysis: The best solutions are derived from solid planning. Kaysun questions, tests, and analyzes every aspect of a part’s design and proposed materials to achieve exceptional performance — before production begins. Scientific molding, mold fill analysis, and finite element analysis (FEA) are just some of the tools our specially trained engineers rely upon to consistently get desired results.
  7. Value-Added Services: Post-mold, value-added services, sometimes referred to as secondary operations, optimize Kaysun’s ability to deliver cost-effective solutions to complex manufacturing challenges. Offering services such as ultrasonic welding, plastics machining, heat staking, insert assembly, potting/sealing, and customized assembly drives down costs and increases quality.

Working with a competent injection molder is one thing. Having a true partner that can eliminate the struggle and worry of potential injection molding missteps and elevate outcomes is another.

At Kaysun, we pride ourselves on supporting our customers with engineering services that help define, work toward, and achieve exceptional outcomes. See how we were put to the test when a belt tensioning pulley assembly presented metal-to-plastic conversion opportunities. Click the button below to download the Gates Corporation Case Study now.

Gates Case Study

Topics: Plastic Part Design, Scientific Molding

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