Product Design & Engineering
- Collaborative early-stage DfM reviews to avoid delays
- Mold flow simulation to improve fill, cooling, and warp control
- Material selection guidance for durability, cost, and aesthetics
In-Process Control
- Scientific molding and process validation
- Automated handling and closed-loop adjustments for consistency
- Scalable quality assurance across production runs
Post-Molding & Value-Added Services
- Ultrasonic welding, heat staking, insert molding
- Custom assembly, testing, and labeling
- Clean infrared technology for non-contact sealing
Kitchen Faucet Valve Body
Challenge:
A top-tier plumbing OEM needed to replace a brass valve body in a kitchen faucet after discovering it introduced lead into the water supply. The conversion to plastic required high-temperature thermoplastics and extremely tight tolerances, which proved too complex for their original molder.
Solution Highlights:
- Designed a precision process for a high-temp, 700°F resin
- Built a four-cavity mold for consistent performance
- Engineered tooling with multiple moving components for reliability
- Unthreaded steel components as part of complex mold actions
Impact:
Kaysun delivered accurate, repeatable part quality at high volumes, achieved regulatory compliance, and helped the OEM reduce total manufacturing costs.
Food Waste Disposal Housing
Challenge:
A leading appliance brand faced field failures due to leaking and loosening of food waste disposal housings. Their existing commodity molder couldn't solve for vibration tolerance, sealing integrity, or consistent fit—jeopardizing the brand's reputation.
Solution Highlights:
- Performed design-for-failure analysis and complete re-engineering
- Converted metal collars and seals to plastic and TPE overmolded components
- Redesigned housing substrates to meet vibration endurance requirements
Integrated multi-material molding and automation into a single work cell
Impact:
Kaysun’s custom injection molding expertise produced a repeatable, high-performance housing that reduced scrap, improved sealing and dimensional fit, and lowered production costs with automation.
