Factory Overview
Integrated ISO Terminal & Connector Manufacturer
50+ Years of Excellence, 30,000+ Products, and Worldwide Reach
KST is a globally recognized manufacturer of electrical terminals and automotive connectors, proudly holding both ISO and IATF 16949 certifications. With over five decades of experience, KST has established itself as a premier supplier of cold-pressed electrical terminals. Our success stems from our expertise in stamping and injection mold design, engineering, quality assurance, and production processes. This has allowed us to expand our product range to over 30,000 offerings, encompassing electric terminals, automotive connectors, solar PV connectors, and EV charging connectors. This page provides a factory overview.
ISO 17025 and UL Independent Testing Lab
Situated in Changhua, Taiwan, our headquarters and main factories serve as the hub of KST’s operations. Within this location, we maintain a fully certified ISO 17025 Quality Assurance Laboratory, which has been an authorized UL Independent Testing Lab (ITL) since 2003. As part of our commitment to global expansion, we have manufacturing facilities in Taiwan and China and are expanding manufacturing capabilities into Thailand. Furthermore, KST operates warehouses and sales offices in the United States, Vietnam, Indonesia, and Thailand, enabling us to cater to a diverse range of markets. Our dedication to international outreach is exemplified by our exports to 150 countries worldwide.
Automated Robotic Arm Insert Molding
Automatic Unloading Plastic Injection
Automatic Vaccum-Feeder Plastic Injection
Automatic Storage Retrieval System
Automatic Assembly Machines
Automatic Stamping Machines
Automatic Welding w/ Vision Inspection
Electroplating Machines
PVC/PA Extruder In-line measurement
Automatic Packaging Machines
Automated Vision Inspection
Next-Gen Assembly Machines
Terminal & Connector Processes
Terminal & Connectors
Our Beginning and Core Technologies
K.S Terminals Inc. stands as a prominent global leader in the manufacturing of cold-pressed electrical terminals. Since its establishment in Changhua, Taiwan in 1973, the company has harnessed cutting-edge technologies such as high-precision mold design, stamping, and injection molding to solidify its position in the industry.
In a significant milestone, KST became a publicly listed company on the Taiwan stock market in 2002. The company’s unwavering commitment to core business values has fostered sustainability and propelled KST to cultivate enduring partnerships with like-minded organizations dedicated to quality and research & development. Currently, KST operates two factories in Taiwan and an additional facility in Suzhou, China. Manufacturing in Thailand will be coming online soon.
Taiwan Headquarters
KST’s Zhangbin factory and headquarters, founded in 1988 within the Changhua Binhai Industrial Zone, serve as the primary production hub for the company. This facility plays a crucial role in the manufacturing of our diverse electrical terminal and connector product lines. With a range of manufacturing processes at hand, including continuous stamping, welding, electroplating, assembly packaging, and warehousing, KST leverages various degrees of automation. Moreover, we boast a dedicated mold processing center that collaborates closely with customers to design and develop tailored product tooling solutions.
Customizable Automation
Agile Equipment Integrated by Automation Team
Our automation engineering team excels in designing and manufacturing a diverse range of cutting-edge automation equipment. We specialize in developing automated systems for various tasks, including automatic feeding, assembly, machine vision inspection, counting, and packaging. By utilizing our advanced technologies, we ensure consistent product quality and quantity. Our equipment and processes can be swiftly integrated and configured to meet a wide range of product requirements, allowing us to expedite production and shipping, thereby meeting the demanding delivery schedules of our valued customers.
30000+ Terminal & Connector Products Certified for Global Markets
As a highly productive factory, we are renowned for our production and distribution of connectors. Our offerings span from large wire terminals used in power transmission to certified EV Charging connectors tailored for specific markets worldwide. With an annual production and shipment volume exceeding 3.8 billion units, we proudly offer over 30,000 unique connector types. This extensive product range exemplifies our unwavering dedication to meeting the diverse needs of our global customer base.
50+ years of experience and ISO 17025
Having 50 years of industry experience, our team consistently pushes the boundaries of production technology to deliver exceptional results. We take pride in maintaining ISO 17025-certified quality assurance laboratories, which are also UL-certified independent testing facilities. These measures are in place to ensure the highest standards of quality and safety for our products. Consequently, our KST brand has earned global recognition as a leader in the terminal and connector market. We remain committed to surpassing customer expectations in terms of product performance and reliability, cementing our reputation for excellence.
Automation
Automation Workshop
ISO 14001
There are more than 300 automated assembly machines in the factory dedicated to various types of terminals and connectors. These assembly machines have been developed by our automation team and they have been designed to boot up quickly, be simple to maintain, and yet be highly flexible in usage.
Step 1
Raw Copper Materials
ISO 14001
Incoming Quality Control (IQC), material inspected for visual appearance, hardness, conductivity, size and direction confirmation
Step 2
Stamping Press
Automated
A fully automatic mechanical feeder is used to place the copper material into the mold for stamping and forming at high speed. The size tolerance is maintained automatically via CCD Inspection.
At present, there are about 41 stamping presses. The annual production output for stamped products is about 1.5 billion pieces. Stamped products range in size from a minimum of 6 mm to a maximum of 150 mm.
Step 3
Annealing & Welding
Automated, CCD Inspected
An automatic annealing & welding machine is used to weld the terminal and automated CCD inspection is used to ensure 100% product yield.
Step 4
Electroplating
ISO 14001
KST’s electroplating factory is located in the National Industrial Environmental Zone. It supports fast, high-quality electroplating surface treatments. Production processes are in full compliance with government environmental regulations and emission standards.
Step 5
CCD Inspection
Automated
The finished product passes between vibrating plates, and the CCD Inspection machine can automatically detect the defective appearance of products.
The Automation Department engineer codes programs to detect abnormal quality products through PLC (programming logical controller) signals and automatically returns the materials to the defective products area.
Step 6
Terminal Assembly Machine
Automated, CCD Inspected
Automatic assembly equipment is used to insert the terminal into the insulating sheath, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.
Step 7
Terminal Reel Assembly
Automated, CCD Inspected
Automatic assembly equipment is used to place the assembled terminal onto the reel tape, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.
Step 8
Connector Assembly
Automated, CCD Inspected
Automatic assembly equipment is used to insert the terminal into the connector, and CCD inspection/detection is used to ensure product tolerances and quality specifications are met.
Step 9
Packaging
Manual & Automated
Fully automatic packaging machines can execute one-stop processes for picking, weighing, encapsulating, labeling, and barcode printing. It can not only significantly enhance packaging productivity and efficiency, but also ensure the stability and consistency of package quality.
Step 10
Labelling
Manual & Automated
Linked to the production order management system in ERP, the label printing system can fetch product specifications and customer shipping information from the synchronized database. It can print product labels for bags, boxes, cases, pallets, crates, and custom documents efficiently.
Step 11
Finished Product OQC
Automated
Products undergo Outgoing Quality Control (OQC) including optical inspection, quantity confirmation, as well as various electrical and performance testing.
Step 12
Continuous Improvement
ISO 14001
Continuous improvement is the ongoing improvement of products, services, or processes through incremental and breakthrough improvements. These efforts can seek “incremental” improvement over time or “breakthrough” improvement all at once.
Nylon Cable Production Process
Nylon Cable Tie Production Processes
KST Injection Mold and Cable Tie Product Factory feature an exceptional research team and a state-of-the-art laboratory that provides comprehensive support for material analysis, product design, mold prototype design, mold processing, and injection trial production. Our facility is equipped with cutting-edge technology to ensure independent design capabilities, facilitate research and development team mentoring, and provide thorough verification and testing. It is worth noting that our laboratory has obtained the prestigious UL certification, signifying its status as an independent laboratory.
Comprehensive Range of Nylon Cable Tie Products
Since its inception in 2008, KST has been dedicated to the development of its cable tie product line. By 2010, KST had successfully established a manufacturing facility exclusively for nylon cable ties. At present, our company proudly manufactures a wide range of nylon cable ties, including Mounting, Releasable, Heavy Duty, Markable, Plug, Push, Releasable Push Mount Cable Ties, as well as Weather-resistant UV Cable Ties. Our commitment to quality and innovation remains unwavering.
Premium Materials Ensures Durability
At our facility, we utilize top-quality engineered plastics and plastic injection materials sourced from premium suppliers in the production of our plastic products. This commitment to using high-grade materials ensures the durability and performance of our offerings.
Leading Edge Machinery
Moreover, we have made significant investments in precision plastic extrusion and injection machines imported from renowned manufacturers in Japan and Europe. This strategic decision guarantees the stability of our production processes and upholds the highest standards of quality. Additionally, our highly automated production line enhances our capacity, enabling us to efficiently handle both large-scale orders and an increasing number of small orders without compromising customization.
In our manufacturing processes, we rely on PA66, a widely acclaimed material known for its exceptional mechanical strength, rigidity, and excellent stability under heat and chemical exposure. This choice ensures that our products meet the stringent requirements of industries where these properties are essential.
Machine Vision
From injection mold production, continuous reel product production, carbon embedded injection production, all of our product lines have achieved a high degree of automation including 2.5D vision inspection equipment, and undergo prescribed industry-standard environmental, strength, material, and electrical testing processes.
Nylon Cable Tie Features & Benefits
At our facility, we utilize top-quality engineered plastics and plastic injection materials sourced from premium suppliers in the production of our plastic products. This commitment to using high-grade materials ensures the durability and performance of our offerings.
Moreover, we have made significant investments in precision plastic extrusion and injection machines imported from renowned manufacturers in Japan and Europe. This strategic decision guarantees the stability of our production processes and upholds the highest standards of quality. Additionally, our highly automated production line enhances our capacity, enabling us to efficiently handle both large-scale orders and an increasing number of small orders without compromising customization.
In our manufacturing processes, we rely on PA66, a widely acclaimed material known for its exceptional mechanical strength, rigidity, and excellent stability under heat and chemical exposure. This choice ensures that our products meet the stringent requirements of industries where these properties are essential.
Step 1
Raw Material
ISO 14001
Raw material Input Quality Control (IQC) includes dimensional check, visual inspection of raw materials, RV (Reduced Viscosity), MI (Melt Flow Index), examine and determine mechanical physical strength.
Step 2
Retrieve Mold and Raw Materials from storage
Materials and molds are managed by the ERP system and picked out of the warehouse via an integrated automated storage retrieval system.
Step 3
Material Drying
The central computer system automatically controls the raw material mixing, and temperature drying setting, to ensure the stability of the moisture content of the raw materials. PA66 (Nylon) is often used because it provides high mechanical strength, rigidity, good stability under heat and chemical resistance.
Step 4
Pneumatic Pressure Delivery System
Each injection machine communicates with the central computer system to automatically monitor the required material that is delivered through the pneumatic conveyor delivery system. By, design, it is scalable, transporting PA66 from a single source feeder to multiple destinations.
Step 5
Injection Molding
The plastic pellets are heated, and after they are melted, they are injected into the molding. During the injection molding process, the plastic can be reinforced with embedded carbon for additional tensile strength. KST has invested in high-speed molding machines from Japan and Europe to produce superior quality nylon cable tie products.
Step 6
Automatic CCD Inspection machine
The finished product passes between vibrating plates, and the CCD Inspection machine automatically detects visual imperfections. The Automation Department engineer codes programs to detect abnormalities in products through PLC (programming logical controller) signals and automatically returns a product that is below tolerance to the defective products area.
Step 7
Automatic Cutting
The finished product in the mold is cut and separated from the runner material through an automatic cutting machine, and automatically counted by the infrared sensor. Every 100 pieces is picked by the robot hand gripper and put into the automatic packaging machine.
Step 8
Automatic Water Spray
Nylon Cable Ties are bundled, automatically inserted into a plastic bag, and sprayed with water to allow the cable ties to continue to cure inside the packaging and ensure the stability of the moisture content of the finished product.
Step 9
Labelling
Linked to the production order management system in ERP, the label printing system can fetch product specifications and customer shipping information from the synchronized database. It can print product labels for bags, boxes, cases, pallets, crates, and custom documents efficiently.
Step 10
Finished Product is returned to Inventory
When the product attains the target moisture, Personnel will scan the ID bar code and the ERP system will transport the finished product into the automatic storage and retrieval system.
Step 11
Outgoing Quality Control (OQC)
Outgoing Quality Control (OQC) shipping inspection conducted to confirm product appearance, function, packaging, marking, and quantity. Cable ties are placed on a conveyor belt and carried to packaging operations for inspection. Here they are placed on weighing devices and then sensor counters to double-check that the packing quantity is correct.
Step 12
Loading and Shipping
The unloading of incoming raw materials from containers and loading of outgoing finished products are synchronized to facilitate good logistical practices.
Plastic Injection Molding Processes
Plastic Injection Molding Plant Expansion
In 2010 KST set up a second plastic ejection plant to expand the design and development of our own injection molds for plastic products production. In addition to a comprehensive line of nylon cable ties, KST also manufactures insulated plastic connector sleeves, home appliance connectors, automotive connectors, green energy connectors, EV charging connectors, carbon insert injection molding, metal insert molding, cable wire insert molding, and other plastic injection mold products. At present, we have 29 plastic injection machine lines with an annual output of approximately 300 million pieces.
We excel in product and mold development and welcome you to inquire about our services.
Injection Mold Independent R&D and Laboratory
KST injection mold and cable tie product factory has an independent research team and a well-equipped laboratory that supports integrated capabilities for material analysis, product design, mold prototype design, mold processing, injection trial production, independent design capabilities, research and development team mentoring, as well as a fully equipped laboratory for verification and testing, that is also UL independent laboratory certified.
Materials from Premium Sources
Plastic products are produced using quality engineered plastics and plastic injection materials from premium suppliers. In addition, we have invested in precision plastic extrusion and injection machines imported from Japan and Europe, ensuring the stability of production and quality.
Machine Vision Inspection
From injection mold production, continuous reel product production, and carbon embedded injection production, all of our product lines have achieved a high degree of automation including 2.5D vision inspection equipment, and undergo prescribed industry-standard environmental, strength, material, and electrical testing processes.
Plastic Injection Molding Features & Benefits:
Regardless of the industry, OEMs opt for the benefits of plastic injection molding. It’s is known for being able to produce consistent, affordable, complex products of high quality that can withstand any environment.
Insert Molding (IM)
Insert Molding (IM):
Embedded Metal / Ceramic
Insert Plastic Injection Molding (IM) is a specialized process offered by KST. It involves embedding metal, plastic, or ceramic parts within plastic to enhance the structure of a product.
During IM, the desired part is carefully positioned within a mold cavity. The chosen plastic material is then injected directly around the part, resulting in a unified component with the insert(s) securely embedded in the plastic. Engineered plastics are typically used in this process to improve durability, tensile strength, and achieve weight reduction.
Provides Path to Cost Reduction
IM presents an efficient and straightforward alternative to assembling individual parts using soldering, connectors, fasteners, or adhesives. By leveraging the capabilities of plastic, it also enables cost reduction by minimizing the amount of expensive metal required to manufacture a part. A key advantage of this process is that it can be performed using a standard single-shot injection machine, leading to lower tooling costs compared to multi-shot processes.
We excel in product and mold development and welcome you to inquire about our services.
Reduces Assembly and Labor Costs
The process of Injection Molding (IM) offers the advantage of securely bonding multiple components together using thermoplastic materials. When combined with automation, this process significantly reduces assembly and labor costs. An excellent example of this is the utilization of a stamped metal insert to create a perforated IM part, effectively generating an insulated multi-path circuit.
IM provides the opportunity to eliminate the need for fasteners and connectors. By harnessing the bonding strength of resin and metal inserts, IM enables the production of smaller, lighter, and more durable components.
Integration of Complex Parts
Engineers highly appreciate the flexibility and possibilities afforded by IM. It allows for the integration of complex stamped metal or formed parts. The external resin layer provides insulation, while the internal metal component creates a dedicated multi-path electric circuit.
IM components greatly reduce the likelihood of parts loosening, misalignment, or electrical disconnection. Moreover, the use of thermoplastic resin enhances the shock and vibration durability of the materials.
Insertion of Materials:
IM involves the insertion of various metals, including frame die castings, plated copper pins, sockets, and wire embedded into engineering plastic or thermoplastic rubber (TPR).
Plastic Injection Insert Molding (IM) Benefits:
Applications
TPR + Metal Frame (3C Mechanical Parts)
ABS + Aluminum Die Casting (Sports/ Medical Parts)
Engineering Plastic + Plated Pin + Wire (Electrical Connectors)
Engineering Plastic + Copper Pin/Contact (Precision Electronic Components)
Liquid Injection Molding (LIM) Processes
Liquid Injection Molding (LIM)
Solid Rubber/Silicone Products
Liquid Injection Molding (LIM) is a highly preferred manufacturing process for creating solid silicone rubber products, thanks to the outstanding durability and flexibility characteristics of liquid silicone rubber (LSR) or similar elastomeric materials. LIM enables the production of a wide range of products, including:
- Seals and sealing membranes
- Electrical and electronic components, such as connectors and cables
- Medical devices and sterile equipment
- Kitchen goods
- Watersports equipment
- Gas masks
- Military gear
- Waterproof device cases
- Infant care products
Precise Molding of Complex Shapes and Intricate Designs
The versatility of LIM allows for the precise molding of complex shapes and intricate designs, ensuring the desired functionality and performance of the end products. With its exceptional material properties, LIM delivers superior quality and reliability across various industries.
LIM leverages Liquid Silicone Rubber
Liquid injection molding utilizes the exceptional characteristics of Liquid Silicone Rubber (LSR), necessitating a streamlined and consistent mechanical mixing process instead of a labor-intensive one. This closed-loop process employs a pump and mixing unit to thoroughly blend and dispense the liquid material into a molding press. Following the curing stage, the press opens, and the product is either manually or robotically extracted.
Versatile and Cost-effective Manufacturing Process
Liquid injection molding stands out as one of the most versatile and cost-effective manufacturing methods available today. It finds application in a multitude of industries and markets, including:
- Aerospace and aviation
- Automotive
- Electronics
- Food and beverage
- Medical and dental
Materials Sourcing
We source our LSR materials from trusted manufacturers such as Shin Etsu, Dow Corning, and GE Silicones. These reputable suppliers ensure the highest quality and performance of our liquid injection molded products.
Liquid Injection Molding (LIM) Benefits:
When implemented with precision, Liquid Injection Molding (LIM) consistently delivers high-quality molded components in large quantities. However, it is crucial to assess its suitability for each specific application. One key consideration is determining whether silicone is the optimal material choice. While silicone offers numerous advantages, it may not be ideal in certain circumstances.
It is essential to evaluate the environmental and chemical conditions the molded components will encounter. For instance, silicone can react unfavorably with pressurized steam at temperatures exceeding 150°C. This reaction can lead to the breakdown of the material’s siloxane polymer and the degradation of its essential properties.
To ensure the longevity and optimal performance of the molded components, it is important to explore alternative materials that can withstand the specific environmental and chemical conditions they will be exposed to. Conducting a comprehensive material analysis and consulting with experts can help identify the most suitable material for the intended application, guaranteeing the desired functionality and longevity of the molded components.
Liquid Injection Molding (LIM) offers several features and benefits that make it a preferred manufacturing method for various applications. Here are some key features and benefits of LIM.
Overall, the features and benefits of LIM make it a versatile and effective manufacturing process, particularly for applications that require precision, durability, complex designs, and high-volume production.
Step 1
Raw Material
Dupont, Vydyne PA66
Raw material Input Quality Control (IQC) includes dimensional check, visual inspection of raw materials, RV (Reduced Viscosity), MI (Melt Flow Index), examine and determine mechanical physical strength.
Step 2
Retrieve Mold and Raw Materials from storage
ERP, ASRS
Materials and molds are managed by the ERP system and picked out of the warehouse via an integrated automated storage retrieval system.
Step 3
Material Drying
Fanuc, Wittmann Battenfeld, JWS, Lian Fa, Multiplas
Raw material mixing, and temperature drying settings are controlled locally at each injection molding machine.
Step 4.1
Injection Molding
The plastic injection machine dehumidifier and dryer communicate with each other. The plastic pellets are heated, and after they are melted, they are injected into the molding:
Step 4.2
Insert Molding (IM)
Insert Molding (IM) – When a metal, plastic or ceramic part needs to be embedded in plastic to improve product structure it is called Insert Plastic Injection Molding (IM).
Step 4.3
Liquid Injection Molding (LIM)
Liquid Injection Molding (LIM) – is a manufacturing process commonly used to make silicone parts (LSR) that need to withstand extreme conditions.
Step 4.4
Continuous Strip Molding (CSM)
Continuous strip molding (or reel-to-reel molding) is used to efficiently manufacture and assemble terminals and connectors by combining metal terminals and plastic components and connectors. The process uses a feed reel and a take-up reel: a continuous metal “carrier” strip is precisely indexed off the feed reel, passes through an injection mold and onto the take-up reel. The molded parts are delivered to customers still on the take-up reel and placed directly in automated production equipment for hands-off operations that add more components, install covers or form electrical connections, etc.
Step 5
Automatic CCD Inspection machine
The finished product passes between vibrating plates, and the CCD Inspection machine can automatically detect the defective appearance of products.
The Automation Department engineer codes programs to detect abnormal quality products through PLC (programming logical controller) signals and automatically returns the materials to the defective products area.
Step 6
Product moisture
Plastic products are placed in the return chamber to control temperature and humidity. The amount of time the product remains in the chamber is monitored and managed by the ERP system, which maintains the standard rate of plastic moisture absorption.
Step 7
Finished Product is returned to Inventory
When the product attains the target moisture, Personnel will scan the ID bar code and the ERP system will transport the finished product into the automatic storage and retrieval system.
Step 8
Packaging
Pass the separated finished product through an automatic packaging machine to perform automated counting, sealing, labeling, and batch number printing, and the process is complete.
Step 9
Outgoing Quality Control (OQC)
Cable ties are placed on a conveyor belt and carried to packaging operations. Here they are placed on weighing devices and then sensor counters to double check that the packing quantity is correct and to simplify the manual counting process.
Step 10
Loading and Shipping
Synchronization of incoming raw materials and outgoing finished product loading facilitates good logistical practice.
