Certified Automotive Injection Molding Company
Kaysun is an IATF 16949:2016-certified automotive injection molding company with mature PPAP/APQP processes, advanced metrology & in-house testing/quality assurance, and program management aligned with OEM and Tier-1 expectations.
Engineering & Materials Expertise
- Engineering-grade resin selection to balance high heat, chemical resistance, and fatigue (PA, PPS, PEEK, PC/ABS, TPE) in harsh environments
- Metal-to-plastic conversion guidance on weight, cost, corrosion, and Noise/Vibration/Harshness (NVH) reduction strategies
- DfM reviews optimize ribs, draft angles, gate locations, and knit line control
- Mold flow analysis validates tool performance by simulating fill, pack, cooling, and warp
Process Control
- Scientific molding uses sensor-based data to precisely replicate ideal shot conditions across all cavities
- In-process monitoring, closed-loop adjustments, and cavity pressure curves ensure molding consistency and part integrity throughout production
- Centralized material handling and automation improve process repeatability and waste reduction
Quality & Compliance
- Tolerances to ±0.001" are supported through precision tooling and validated process management
- In-house quality lab and advanced metrology including CT scanning, CMM, vision, leak/functional testing verify internal and external part quality
Sunroof Front Frame
Challenge:
OEM struggled with part warp and flash issues when transitioning a metal component to plastic
Solution Highlights:
- Automated work cells with robotic insert loading (9 metal inserts per part)
- “No flash” tooling using spring-loaded components
- Molded-in clip features and rigorous QA
- Custom returnable packaging program
Impact:
Resolved previous supplier's warping issues, achieved successful metal-to-plastic conversion, reduced weight, and ensured zero flash with high repeatability
Belt Tensioning Pulley Assembly
Challenge:
Replace metal part to reduce weight and cost, while meeting tight noise and dimensional tolerances
Solution Highlights:
- Early design collaboration using DFM and scientific molding
- 10-gate system with pressure-controlled valve gates for roundness
- Molded-in bearing insert replaced secondary assembly
Impact:
Achieved perfect roundness, cut production costs, and maintained performance specs for a critical serpentine belt component
Heavy Truck Braking Valve Component
Challenge:
Previous molders failed to balance durability and straightness in compressed-air brake component
Solution Highlights:
- Tested 15+ materials for optimal fit
- Design of Experiments (DoE) used to refine gating and temperature profiles
- Tooling innovations (ring gating, variable shrinkage zones)
Impact:
Eliminated prior defects, enhanced dimensional consistency, and delivered a robust solution for a safety-critical part
