Plastic Injection Molding Plant

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.

Research and development

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.

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We excel in product and mold development and welcome you to inquire about our services.

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A professional mold technician checks the mold status before and after injection machine usage.

Materials & Equipment

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.

Process

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 CCD quality inspection equipment, and undergo prescribed industry-standard environmental, strength, material, and electrical testing processes.

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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.

Plastic Injection Molding Benefits:

High Efficiency - Fast Production
Complex Part Design
Enhanced Strength
Increased flexibility - Material and Color
Reduced Waste
Can opt to use multiple types of plastics(overmold)
Product Development Timeline
High-Output Production and Consistency
Reduced weight

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). It is a unique process and one that K.S. TERMINALS INC. specializes in.

With IM, a part is placed in a mold cavity. Selected plastic material is injected directly around it resulting in a single part, with the insert(s) embedded in the plastic material. This process normally uses engineered plastics for improved durability, tensile strength, and weight reduction.

IM can be a highly efficient and simple alternative when compared to the assembly of individual parts using soldering, connectors, fasteners, or adhesives. It also leverages plastic capabilities and can reduce finished product costs by reducing the amount of expensive metal needed to create a part. Critical to this process, because we can use a standard single-shot injection machine for IM, tooling costs are lower than with a multi-shot process.

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We excel in product and mold development and welcome you to inquire about our services.

https://ksterminals.com/wp-content/uploads/2500x1667_Mold-Processing-Center-bn3-2.jpg

A professional mold technician checks the mold status before and after injection machine usage.

IM bonds numerous components together with thermoplastic. A benefit of this process, when coupled with automation, is reduced assembly and labor costs. For example, a stamped metal insert can be used to create a perforated IM part, which effectively creates an insulated multi-path circuit.

IM can be used to eliminate fasteners and connectors. By introducing the bonded strength of resin and metal inserts, IM yields smaller, lighter, more durable components.

Engineers welcome the flexibility and possibilities that IM provides. For example, a complex stamped metal or formed part can be used in IM. The external resin provides insulation while the internal metal part provides a dedicated multi-path electric circuit.

IM components reduce the possibility for parts to loosen, become misaligned and/or become electrically disconnected. An overall benefit of thermoplastic resin is improved shock and vibration durability.

Materials:

Inserted metals including frame die castings, plated copper pins, sockets, and wire embedded into Engineering plastic or Thermo Plastic Rubber (TPR).

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Insert Plastic Injection Molding (IM) Benefits:

Lower assembly and labor costs
Reduced size and weight
Improved reliability
Increased engineering flexibility

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)

Liquid injection molding (LIM) utilizes liquid silicone rubber (LSR) or similar elastomeric material and is the preferred process for manufacturing solid silicone rubber products for its excellent durability and flexibility characteristics. Some of the common products produced by LIM are:

  • Seals and sealing membranes
  • Electrical and electronic components, such as connectors and cables
  • Medical and sterile devices
  • Kitchen goods
  • Watersports
  • Gas masks
  • Military Gear
  • Waterproof device cases
  • Infant care products
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A professional mold technician checks the mold status before and after injection machine usage.

Due to Liquid Silicone Rubber characteristics (LSR), liquid injection molding requires a streamlined and consistent mechanical mixing process rather than a labor-intensive one. The closed-loop process leverages a pump and mixing unit to mix and dispense the liquid material into a molding press. Once the curing stage is complete, the press opens, and the product is manually or robotically removed.

Liquid injection molding is one of the most cost-effective and versatile manufacturing methods currently available. It can be applied towards any industry or market, including:

  • Aerospace and aviation
  • Automotive
  • Electronics
  • Food and beverage
  • Medical and dental

Materials

Shin Etsu / Dow Corning/ GE Silicones

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Liquid Injection Molding (LIM) Benefits:

When implemented correctly, LIM consistently produces high-quality molded components in large quantities. However, it is not always the most optimal choice. For example, it is important to consider whether silicone would be the best material to choose. Silicone tends to react with certain environmental and chemical conditions, such as pressurized steam at temperatures above 150°C, which breaks down the material’s siloxane polymer and degrades its material properties.

ADVANTAGES & APPLICATIONS:

Low viscosity and lower injection pressure, good for silicon molding

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.