Kaysun Blog

What to Know About Injection Molding in Wisconsin

Heather Kinzel — Wed, 17 Sep 2025 13:45:00 GMT

TL; DR: The 30-second Summary

If you’re looking for custom injection molding companies in Wisconsin, you’re tapping into one of the most advanced and stable manufacturing ecosystems in the nation. Kaysun helps OEMs scale with innovative, geographically advantageous U.S.-based injection molding solutions.

Ways Reshoring Strengthens an OEM Supply Chain Strategy

jvogel@kaysun.com (Jenna Vogel) — Wed, 20 Aug 2025 17:25:00 GMT

TL; DR (Quick Article Summary)

Why is reshoring a smart OEM supply chain strategy?

Reshoring injection molding operations helps OEMs mitigate supply chain risk by improving parts availability, manufacturing efficiency, product quality, and logistics responsiveness. A U.S.-based manufacturing partner enables a more resilient, streamlined OEM supply chain strategy tailored to curtail the impact of current global unpredictability and market disruptions.

Kaysun and Sodick Partnership

breeves@kaysun.com (Bob Reeves) — Tue, 22 Jul 2025 13:45:00 GMT

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.

Reshoring Roadmap for OEMs

kglassen@kaysun.com (Ken Glassen) — Wed, 28 May 2025 13:45:00 GMT

Tariffs, geopolitical uncertainty, global supply chain disruptions, and shifting consumer expectations are reshaping manufacturing strategies in every industry. After decades of leveraging lower labor costs overseas, many OEMs are reconsidering the true value of offshoring.

Reshoring — the practice of bringing overseas production back to North America — is no longer viewed as a trend. It’s a strategic move for OEMs seeking stability, quality, and long-term profitability. The many considerations related to reshoring can sometimes make the transition complicated, but persistence pays off when the proper steps are followed.

For sourcing and procurement professionals, understanding what’s involved — and what pitfalls to avoid — during reshoring is critical, especially as unpredictable tariffs could arbitrarily upend an otherwise cost-effective transition.

AI with RJG CoPilot Optimizes Injection Molding Quality and Efficiency

Travis Carter — Thu, 24 Apr 2025 13:45:00 GMT

Industry 4.0 has made manufacturing more dynamic than ever before. Merging IoT, AI, and big data enables faster, more accurate, and more efficient production based on data-driven decisions. Along with progress typically comes a need to modernize and optimize technologies.

In the injection molding industry, the advancements impact the RJG Inc. eDart process control system. For a little over two decades, the vast majority of molders — including Kaysun — have relied upon eDart for monitoring injection molding processes and controlling key variables such as pressure, temperature, and fill rates.

The trusted system is still in place on many production lines, but RJG is phasing eDart out in favor of the new, more powerful RJG CoPilot and The Hub systems by 2030.

As industry leaders and early adopters, Kaysun has already implemented a plan to transition to CoPilot and The Hub in stepped intervals. In mid-2024, we purchased five CoPilot systems, five more are slated for 2025, and the balance of the 47 lines currently operating eDart will be upgraded by RJG’s 2030 deadline.

It’s not technology for technology’s sake. Our incremental CoPilot integration helps us strategically future-proof our injection molding operations to enhance production efficiency, reduce scrap, and maintain the highest quality standards.

5 Tips to Help Get Tooling Right in Injection Molding Quotes

jvogel@kaysun.com (Jenna Vogel) — Wed, 19 Mar 2025 19:35:00 GMT

Few things impact injection-molded part quality as much as tooling design, materials, and build. Each area impacts tooling performance, and any skews could put finished parts at risk of defect or failure.

Reshoring Remains A Win for American Manufacturing - Here's Why

bharrison@kaysun.com (Ben Harrison) — Tue, 14 Jan 2025 19:05:00 GMT

International trade tensions have brought heightened awareness to reshoring. Recent US-China decoupling and talk of the imposition of substantial tariffs, among other things, have many U.S. manufacturers reviewing their overseas relationships.

What is raising some eyebrows, however, is the urgency with which reshoring is being met. After all, reshoring isn’t a new concept. What makes the present different from the past?

The answer is both simple and complicated because it’s framed in the “new normal” of international trade agreement upheaval and lingering repercussions from the COVID-19 crisis. However, American manufacturers are seeing opportunities to improve new products and existing offerings, services, and bottom lines in four key areas by bringing projects and jobs back to domestic soil.

Key Custom Injection Molding Trends Emerging In 2025

khutts@kaysun.com (Kevin Hutts) — Wed, 11 Dec 2024 17:10:00 GMT

Despite being considered more energy efficient and producing less waste than other molding methods, injection molding continues to be viewed with skepticism when it comes to environmentalism. Ironically, process efficiencies and the impact of materials are generally the areas of most concern and scrutiny.

Ways Kaysun’s Culture of Sustainability Benefits OEMs and The Planet

kphilippi@kaysun.com (Keith Philippi) — Thu, 14 Nov 2024 20:00:00 GMT

Injection-molded parts and products are staples for OEMs in industries ranging from automotive and medical to industrial and consumer goods. Consistent demand has pushed annual valuations of the injection molding market to roughly $300 billion, and an estimated 5 million tons of plastic parts are made and distributed worldwide each year.

The statistics are impressive, but they also concern certain environmental groups championing the need for responsible plastics use, waste reduction, and recycling in an increasingly fragile ecosystem. Competing priorities of serving customers and protecting the planet can put manufacturers and injection molders in a tough spot, but those embracing sustainable practices are setting precedents that strike balance and signal transformative change.

As a leading custom injection molder and preferred partner to a global network of OEMs, Kaysun is sensitive to the detrimental environmental effects of plastics misuse. We are also passionate about doing our part to minimize the impact.

Guided by our internal Green Team and supported by leadership dedicated to social responsibility, the entire Kaysun team truly invests in — and lives — the tenets of a dynamic culture of sustainability.

The Impact of Non-Uniform Injection Molding Wall Thickness

kglassen@kaysun.com (Ken Glassen) — Wed, 23 Oct 2024 14:00:00 GMT

Shrink rates for plastic parts vary depending on the materials used and the uniformity of wall thickness.

Why does injection molded material need uniform wall thickness? Without it, production could be negatively affected by large pressure drops during fill and significant variation in shrink rates. Internal stresses may subsequently appear within the injection-molded parts, causing warpage or similar defects.

For instance, thicker areas within the part can act as “runners” that alter the way the plastic fills the tool. Molten plastic prefers to follow the easiest path, so its flow will always favor the thicker wall section first. As a result, molten material may race ahead in some locations, and then “backfill” the remaining space. This can be troublesome, especially if there's not adequate venting in these areas to allow the escape of any trapped air.