Kaysun Blog

Injection molding is a dynamic, complex process that, simply by the nature of its many variables, requires some testing and adjustments to get it just right before you can start production.

Recent years have brought a fair share of challenges to global manufacturing and commerce. Massive supply chain disruptions found many U.S. manufacturers leveraging the benefits of reshoring to mitigate risk.

On the whole, reshoring is a solid strategy. Bringing production “closer to home” suggests a more comfortable level of control from a logistical standpoint. However, having production occur somewhere in the United States doesn’t necessarily mean a manufacturer’s domestic supply chain is less vulnerable than its global counterpart.

That’s where regionalization proves valuable.

Injection-molded parts are integral to the performance and aesthetics of a wide range of products. Manufacturers depend on the expertise of their injection molding partner to guide decisions and processes that lead to desired outcomes.

Two-shot injection molding (or, two-stage molding) and overmolding are popular choices for many applications. They are also often mistaken as being interchangeable.

Lower material costs. Lower wage costs. A profitable final product price point. There are many reasons why offshore production has been attractive to manufacturers. Then, 2020 happened.

The escalation of the pandemic and global trade tensions exposed inherent risk by disrupting the once-comfortable global manufacturing and supply chain dynamic. Today, concerns still persist regarding supply chain challenges and slow movement through ports. As manufacturers take firmer control of the global supply chain and invest in more local production, they’re enjoying the benefits of “Made In America” manufacturing solutions.

The first injection molding process of the 1800s was run on manual machines and was itself very basic. Plastic was forced through a heated cylinder and into a mold using a plunger. Pressure and time were the main predictors of success, but it was dubious. There was no consistent way to measure the manual process of squeezing plastic into the shape of the mold.

Popular across many industries, overmolding may initially appear to simply enhance the aesthetics of a device, adding a contrasting color or texture. However, overmolding’s lightweight functionality also elevates ergonomics, deadens vibration, and improves a device’s grip and feel.

The 1,250 landfills in the United States are projected to reach maximum capacity within the next few decades. Pair that with the fact that, globally, 91% of plastic waste isn’t recycled, and the devastation of the eco-crisis becomes shockingly real.

Protecting the planet is everyone’s responsibility, including — and perhaps especially — corporations routinely using eco-sensitive materials. As a custom injection molder, Kaysun handles thousands of tons of plastics annually which are processed into injection-molded parts.

Often, complex applications requiring custom injection molding have design and/or materials characteristics that need specialized manufacturing, as in the case of tight tolerances. An experienced injection molder has solutions to address all types of scenarios, but scientific molding expertise adds unique value.

Mention “high-temperature thermoplastic” and chances are that polyether ether ketone (PEEK) comes to mind. Its high heat tolerance, mechanical strength, and chemical resistance make PEEK resin ideal for many demanding applications including those in the automotive, electronics, aerospace, medical, and other markets. But is it the only choice?