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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



                                www.KAYSUN.com
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
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
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
Adaptable
Molding Capabilities
•   Two-Shot Molding
•   Insert Molding
•   Over molding
•   Soft Touch




                       www.KAYSUN.com
Materials Lab

 •   Thermal analysis
 •   Mechanical analysis
 •   FTIR (material ID)
 •   Melt flow
 •   Impact and
     compression test




                           www.KAYSUN.com
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
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
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
Tour Our Facilities




                      www.KAYSUN.com

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Kaysun overview

  • 1. 5500 West Drive Manitowoc, WI 54220 www.KAYSUN.com
  • 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
  • 10. Adaptable Molding Capabilities • Two-Shot Molding • Insert Molding • Over molding • Soft Touch www.KAYSUN.com
  • 11. Materials Lab • Thermal analysis • Mechanical analysis • FTIR (material ID) • Melt flow • Impact and compression test 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
  • 20. Tour Our Facilities www.KAYSUN.com