2. Kaysun Corporation
Manitowoc, Wisconsin
• Corporate offices and facilities located on 22 acres with
technical center and scalable manufacturing
Manitowoc WI
www.KAYSUN.com
3. Company Overview
• 60+ years of experience
• Partner approach
• Highly engineered, high-tolerance plastic products and assemblies
• Experts in converting initial concepts to products
• Critical-use products
• Complex products and assemblies
• Metal-to-plastic conversion
• Scientific molding
• Applicable credentials & certifications:
• ITAR Compliant
• Secured campus
• Small business classified
• ISO 13485:2003 Certified
• TS16949 Certified
www.KAYSUN.com
4. Current Customer Base
• A diverse customer base allows for business
stability during economic volatility.
• Current markets include
• Military / Defense
• Medical
• Industrial
• Transportation
www.KAYSUN.com
5. Why Kaysun?
• Challenging products
• Complete design and engineering support
• Testing and quality assurance
• Aggressive timelines
• Value-added services
• Commitment
• Early engagement to optimize the process
• Faster time to market
• Reduced development costs
• Less rework
• Higher product quality and suitability
www.KAYSUN.com
6. Product Design
• Feasibility Analysis:
• Product specifications and
tolerances
• Functional requirements
• Materials selection
• Material compatibility
• Operational considerations
• Product enhancements and
improvements
www.KAYSUN.com
7. Analysis: Part and Tool Design
• We analyze part and tool
design jointly, reviewing the
interaction of the dependent
designs
• Mold flow
• Shrinkage/warpage
• Finite elements
• Offshore Tooling Options
www.KAYSUN.com
8. Fully Managed
Tool Construction Process
• Part and tool design finalized–tool build
starts
• Specialized steel selection
• Detailed program monitoring
• Progress reviewed with timelines and on-
site meetings
• Detailed tool drawings completed
• Tooling component reviews
• Inspection of steel to design
• Construction standards reviewed and
verified
www.KAYSUN.com
9. Scientific Molding Expertise
• Process development utilizing RJG
cavity pressure-sensing technologies
• Gate freeze off
• Cavity balance
• Pressure response
• Optimization of the production process
• Production process control
• Filling pressure curve monitored in production
• End-of-fill pressure utilized to sort out suspect product
• Parts set aside automatically for additional inspection if outside
the established control limits
www.KAYSUN.com
12. Benefits of
Precision Inspection and Testing
• Precision fixtures
• Laser and vision inspection equipment–
• allows for nondestructive inspection
• CMM equipment–detailed inspection
layouts
• On-site verification
• Complete short-term capability studies on
critical and key items
• All adjustments can be inspected
in process
• Final specifications ensured
www.KAYSUN.com
13. Value-Added Operations
• Potting/Sealing
• Continuity testing
• Pad printing
• Labeling
Customized
Ultrasonic Welding Solutions Insert Assembly/Heat Staking
• Develop process control plan
• Finalize assembly fixtures
• Define assembly techniques
• Build initial components
• Inspect/test components
Plastic Part Machining • Provide initial documentation Automated and Manual Assembly
www.KAYSUN.com
14. Customized Assembly Solutions
• Commitment to invest in technology
• Manufacturing and automation is based
on customer, volume and application.
• Full robotic assembly
• Operation specific automation
• Benefits of automation:
• Improved efficiencies
• Reduced variability / human error
• Increased capacities
• Cost
www.KAYSUN.com
15. Gates - Pulley
Project:
• Gates wanted to replace a current metal pulley with a plastic
option for weight and cost savings.
• Precision tolerances were required to meet NVH requirements.
• Needed to maintain durability of metal pulley.
Solution:
• Utilization of scientific molding, in house tooling, and 3D
scanning capability allowed dimensional analysis of part and
tooling cavity.
• Process stabilization and monitoring with scientific molding
technology allows Kaysun to hold an “as molded” outside
diameter within +/- 0.001”.
• Lowered overall production costs for Gates with weight
reduction while maintaining all necessary NVH requirements.
www.KAYSUN.com
16. Moen – Faucet Valve Body
Project:
• The plumbing industry is faced with the challenge of “getting the
lead out”.
• Moen was looking for a cost and part number reduction that
would be adaptable to current products.
• Product would require precision tolerances and complex tooling.
Solution:
• Kaysun was able to utilize an engineered resin to meet all
functional requirements.
• Kaysun engineering was able to design a challenging tool with 4
cavities with complex pulls, slides, and cores for a final net shape
component.
• Utilization of scientific molding ensures cavity balance and
repeatable process holding the critical dimensions without
secondary machining tolerances.
• Moen was able to maintain regulatory compliance.
www.KAYSUN.com
17. Rockwell Collins - DAGR
Project:
• Rockwell Collins was looking to develop next generation
GPS device.
• Very aggressive timing.
• Lighter, smaller and user friendly
Solution:
• Early engagement with Kaysun engineering allowed team
to strengthen design for increased efficiencies in molding
and assembly.
• Expedited timing & tool management had all production
tooling complete with functional samples to customer in
less than 6 weeks.
• Utilization of analysis tools, scientific molding & and in
house tooling for dimensional accuracy up front.
• Build automated assembly stations for robust quality.
www.KAYSUN.com
18. Smiths Medical – Pulse Oximeter
Project:
• Smiths Medical was looking to refresh and combine current
product offerings for pulse oximeter.
• Looking for cost effective domestic sourcing.
• Required assistance with product design.
Solution:
• Kaysun assisted with benchmark analysis and testing of several
current products.
• Kaysun was able to develop a family of products that shared
tooling and components to minimize expense.
• Solution allowed for Smiths Medical to consolidate assembly
and total part number management.
• Smiths Medical was able to maintain all functional needs and
demands of current market.
• Allowed Smiths Medical to utilize patented technology and
strengthen market position.
www.KAYSUN.com
19. Why Kaysun?
• Challenging products
• Complete design and engineering support
• Testing and quality assurance
• Aggressive timelines
• Value-added services
• Commitment
• Early engagement to optimize the process
• Faster time to market
• Reduced development costs
• Less rework
• Higher product quality and suitability
www.KAYSUN.com
