Kaysun and Sodick: A Partnership Built on Precision, Proven by Performance

Precision presses are central to producing injection-molded parts for complex applications in medical, automotive, and other highly regulated industries. Choosing the right tools and strategic partnerships means continuously evaluating how technology can enhance precision, repeatability, and process stability. This search for dependable solutions led Kaysun to Sodick Injection Molding Machines nearly two decades ago.

Kaysun purchased its first Sodick press in 2007–08, not in response to an immediate production need, but as a proactive investment. At the time, Kaysun was preparing to enter the medical market, which required a step up in molding precision and process control. Sodick’s reputation for high-accuracy equipment made them a logical fit.

Over the years, that single press investment has grown into a fleet of six Sodick machines, integrated across Kaysun’s general production floor. What started as a solution for specialty applications has become a go-to technology for a range of challenging programs.

Technology That Solves Real-World Challenges

Most molding machines use a reciprocating screw with a check-ring valve that combines plasticizing and injection in one motion. While common, it introduces variability. For high-tolerance parts or shear-sensitive resins, that variability can drive up scrap and compromise consistency.

Sodick offers a different solution. Its plunger-style shot system separates melt preparation from injection. This enables:

• Improved thermal control by eliminating unnecessary shear
• Consistent shot volumes, critical for process repeatability
• Higher injection pressures, ideal for thin-wall or high-viscosity resins

Kaysun experienced this advantage firsthand when an industrial application wasn’t suited to conventional screw-and-ring molding.

Kaysun Processing Engineering Manager Travis Carter explained, “We were breaking screws and screw tips trying to run this product in a traditional machine. No matter how we’d spec the machine to size or approached the situation, it simply didn’t work. The machine didn’t have the level of performance needed.”

The Sodick press proved to be the solution.

“We had to get this application into a high performance machine. We reached out to our Sodick contact, Bennett Howard, for assistance,” Carter said. “He was able to provide the right machine for the job and, frankly, this part has been produced flawlessly since. As a result, Kaysun was recognized at that time as the only molder in the world capable of running the program’s specific resin through a hot manifold.”

Success isn’t limited to this application. Travis noted that many programs are enhanced by using Sodick machines, especially when tooling requirements are demanding. “Specific injection profiles can introduce risk of flashing or coming up with a short shot. We’ve found transferring programs to the Sodick presses when elastomers, urethanes, and other soft-touch materials are required minimizes problems.”

The Unique Needs of Medical Applications

The Sodick molding machine also aligns perfectly with programs Kaysun takes on for medical applications. “What we do for medical OEMs often presents difficult process conditions,” Carter noted. “We get into thin-walled molding of highly-engineered resins that require high performance repeatability. Our Sodick machines perform to levels that match Kaysun’s high standards of precision and quality.”

In addition, Sodick’s plunger-style design offers other advantages for medical applications. Cosmetically, there are fewer surface defects such as splay. From a safety and compliance standpoint, since there are fewer moving parts on the molding machine, cleaning is easier and significantly reduces contamination risk.

Partnership Synergies

In the nearly two decades of working with Sodick, synergies have emerged that have advanced certain Kaysun sustainability initiatives, including:

• Reducing scrap due to design and engineering optimization, diverse resin options, and less defects and rework
• Reducing energy consumption and environmental impact

In May of 2025, Travis traveled to Sodick headquarters in Japan. While there, he was struck by how the Kaysun and Sodick teams share common approaches to their work and customers.

“The campus is vertically integrated, streamlining processes and maintaining quality because everything is in-house. It very much reflects Kaysun’s principles,” he said. “Plus, everything is so clean and organized. It represents the pride and respect they have in their people, products, and customer relationships.”

Kaysun’s collaboration with Sodick demonstrates a larger truth about modern manufacturing: precision injection molding doesn’t happen in isolation. It requires partnerships that combine smart technology with active support.

By working closely with equipment partners like Sodick, Kaysun is better able to consistently deliver on our promise of precision, speed, and reliability — no matter how complex the challenge. How can we help you make your next program a success?

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