www.KAYSUN.com

5500 West Drive

Manitowoc, WI 54220

www.KAYSUN.com

Kaysun Corporation

Manitowoc, Wisconsin • Corporate offices and facilities located on 22 acres with

technical center and scalable manufacturing

Manitowoc WI

www.KAYSUN.com

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

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

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

Product Design

• Feasibility Analysis:

• Product specifications and

tolerances

• Functional requirements

• Materials selection

• Material compatibility

• Operational considerations

• Product enhancements and

improvements

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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

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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

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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

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Adaptable

Molding Capabilities • Two-Shot Molding

• Insert Molding

• Over molding

• Soft Touch

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Materials Lab

• Thermal analysis

• Mechanical analysis

• FTIR (material ID)

• Melt flow

• Impact and

compression test

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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

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Value-Added Operations

Insert Assembly/Heat Staking Ultrasonic Welding

Plastic Part Machining Automated and Manual Assembly

• Potting/Sealing • Continuity testing • Pad printing • Labeling

• Develop process control plan

• Finalize assembly fixtures

• Define assembly techniques

• Build initial components

• Inspect/test components

• Provide initial documentation

Customized

Solutions

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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

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

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

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

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

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

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