Kaysun Corporation
Kaysun Corporation is a privately held Manitowoc, Wisconsin-based custom injection molding manufacturer serving Fortune 500 OEMs across medical, automotive, industrial, consumer, and defense industries with scientific molding, in-house engineering, and value-added services.
- Company typePrivate
- Founded1946
- HeadquartersManitowoc, United States
- Headcount251–500
- GTM typeB2B
- OfferingHardware or Manufacturing
What Kaysun Corporation does
Kaysun Corporation is a privately held custom injection molding manufacturer founded in 1946 and headquartered in Manitowoc, Wisconsin. The company produces highly engineered plastic components for Fortune 500 companies and industrial OEMs across five primary verticals: medical, automotive, industrial, consumer, and defense. Operations are concentrated at a single Manitowoc facility that was recently expanded by 55,000 square feet in 2024, and Kaysun serves end customers located in the United States, Mexico, Canada, Germany, Austria, Japan, China, Korea, India, Turkey, and Brazil. The company employs approximately 251-500 people and is led by CEO Ben Harrison.
Kaysun's core offering is custom injection molding executed on an all-electric press fleet ranging from 35 to 940 tons of clamping force, supplied by Toyo, Sodick, and Kraus Maffei. The company's technical differentiation rests on a "scientific molding" methodology built around Design of Experiments (DOE), RJG pressure-sensing instrumentation, Sodick plunger-shot technology for thermal control on shear-sensitive resins, and Design for Manufacturability (DfM) with moldfill flow simulation. Adjacent capabilities include in-house tool design and qualification, insert molding, overmolding, material selection from 25,000+ resins, metal-to-plastic conversion engineering, and vertically integrated value-added secondary operations. Kaysun holds ISO 13485:2016, IATF 16949:2016, ITAR registration, and MedAccred Plastics Accreditation, qualifying it as an approved supplier in medical, automotive, and defense supply chains.
Kaysun generates revenue through project-based custom injection molding programs for OEMs, complemented by bundled engineering services and value-added secondary operations. The company operates a direct enterprise sales motion with a formal 2-3 week quoting process, and programs are typically structured as multi-year contracts targeting complex, highly engineered parts where engineering partnership rather than transactional supply is the basis of competition. Sustainability investments, including a Central Material Handling System estimated to save 1.5 million kWh and $109,000 annually, are positioned to meet Fortune 500 customers' ESG requirements. Kaysun's senior leadership team includes a VP of Engineering with nearly four decades of plastics experience, a VP of Operations overseeing cross-functional engineering-quality-tooling collaboration, and a Director of Purchasing managing resin and component supply chains.
Kaysun Corporation firmographics
Firmographics- Name
- Kaysun Corporation
- Legal name
- Kaysun Corporation, Inc.
- Website
- https://kaysun.com
- Company type
- Private
- Founded year
- 1946
- Operating status
- Operating
- Headcount range
- 251–500 employees
- Short description
- Kaysun Corporation is a privately held Manitowoc, Wisconsin-based custom injection molding manufacturer serving Fortune 500 OEMs across medical, automotive, industrial, consumer, and defense industries with scientific molding, in-house engineering, and value-added services.
- Ownership category
- akta.pro rank
Kaysun Corporation industry classification
Industry- Product category
- Custom Plastic Injection Molding
- NAICS
- Industrial Mold Manufacturing (333511)
- akta.pro primary industry
- Custom Injection Molding & Contract Manufacturing (Job Shops/CMs) (IMANAFAJ)
Keywords
Where Kaysun Corporation is headquartered
LocationHeadquarters
- HQ city
- Manitowoc
- HQ country
- United States
- HQ region
- North America
Offices1 record
Markets served
Kaysun Corporation business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Personnel, Operations, Infrastructure, Technology or R&D, Supply Chain, Marketing or Sales
Revenue model
- Custom Injection Molding Services: Kaysun generates revenue primarily through custom injection molding manufacturing services for complex, highly engineered plastic parts. Revenue is driven by production volume, part complexity, material selection, and program scope across pre-production, production, and ongoing support phases.
- Engineering & Professional Services: In-house engineering support services including DfM analysis, material selection, metal-to-plastic conversion, tool design direction, and scientific molding process development are bundled with manufacturing programs as part of the full-service partnership model.
- Value-Added Services: Vertically integrated secondary operations that enhance molded parts post-production, providing additional revenue stream opportunities and differentiating Kaysun from non-vertically integrated molders.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Other | Multi-year contract | Custom injection molding programs are quoted on a project-specific basis |
Go-to-market motion1 record
Distribution channels1 record
Marketing channels9 records
Kaysun Corporation product offering
Product offeringCore offering
Kaysun Corporation provides custom injection molding services for highly engineered, complex plastic parts serving medical, automotive, industrial, consumer, and defense OEMs. Offerings are delivered as a vertically integrated full-service model that combines in-house engineering support (DfM analysis, material selection, metal-to-plastic conversion), tool design and build, scientific and precision molding (including overmolding and insert molding), value-added secondary operations, and an in-house Quality Lab.
Product overview
Kaysun Corporation is a full-service custom injection molding company offering a comprehensive portfolio of manufacturing services built around engineered excellence. The core offering is Custom Injection Molding, supplemented by advanced processes including Scientific Molding, Overmolding, and Insert Molding. Engineering Support services encompass DfM Analysis, Material Selection, and Metal-to-Plastic Conversion. The company also provides in-house Tool Building and Quality Systems capabilities. Value-Added Services offer vertically integrated secondary operations. The 6-Step Improved Program Flow methodology standardizes their approach to every program, from design feasibility through repeatable production. Kaysun serves Medical, Automotive, Industrial, Consumer, and Defense markets.
Differentiator
Problem solved
Functional benefit
Products and services
- Custom Injection Molding Kaysun's primary service providing innovative, sophisticated injection molding solutions for complex applications in medical, automotive, industrial, consumer, and defense markets using all-electric presses from 35 to 940 tons.
- Scientific Molding
- Overmolding
- Insert Molding
- DfM Analysis
- Material Selection
- Metal-to-Plastic Conversion
- Tool Building
- Value-Added Services
- Quality Systems
- 6-Step Improved Program Flow
Quantifiable outcome
- 3.6+ million pounds of plastic waste diverted from landfills
- +5 more outcomes
Companies that use Kaysun Corporation
Customer profileNamed customers6 records
Segments5 records
Ideal customer profiles4 records
Kaysun Corporation technology and API
TechnologyTechnology focussed No
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature5 records
Kaysun Corporation partnerships and signals
Strategic signalPartnerships
Four partnerships are on record, tiered core.
- SodickcoreKaysun's partnership with Sodick Injection Molding Machines began in 2007-08 when Kaysun purchased its first Sodick press to prepare for entering the medical market requiring higher precision and process control. The relationship has grown to six Sodick machines integrated across the production floor. Sodick's plunger-style shot system separates melt preparation from injection, providing improved thermal control, consistent shot volumes, and higher injection pressures. Sodick technology has solved real-world challenges including running shear-sensitive resins and soft-touch materials (elastomers, urethanes) that caused issues in conventional machines.
- Convergen EnergycorePartnership with renewable fuel and power producer Convergen Energy to convert Kaysun's plastic waste to clean energy. Kaysun regrind is part of the nearly 40% of recycled plastic in fuel pellets used by utility companies to generate electricity instead of burning coal. Manitowoc Public Utilities has seen a 55% reduction in greenhouse gases with this energy source. This partnership supports Kaysun's significant near-term waste-to-energy goals.
- ToyocoreToyo is one of the three injection molding machine manufacturers in Kaysun's all-electric press fleet (alongside Sodick and Kraus Maffei), providing equipment ranging from 35 ton to 940 ton capacity for precision injection molding across complex applications.
- Kraus MaffeicoreKraus Maffei is one of the three injection molding machine manufacturers in Kaysun's all-electric press fleet (alongside Toyo and Sodick), providing equipment ranging from 35 ton to 940 ton capacity for precision injection molding across complex applications.
Scale indicators8 records
Recent moves7 records
Expansion highlights6 records
Kaysun Corporation competitors and assessment
Company assessmentDirect peers
- EVCO Plastics: Wisconsin-based custom injection molding contract manufacturer serving medical, automotive, industrial, and consumer OEMs with engineering, tooling, and value-added services. Directly comparable to Kaysun on geography, vertical mix, and full-service custom molding model.
- Tessy Plastics: Custom injection molder with a strong medical device and regulated-industry focus, part of the Viant Medical group. Closely comparable to Kaysun on medical-grade molding, validation expertise, and complex multi-material programs.
- PTI Engineered Plastics: Engineering-driven custom injection molder serving medical, defense, and industrial OEMs with in-house tooling, DFM, and scientific molding. Highly comparable to Kaysun on regulated verticals and engineering-led program execution.
- Plastikos: Custom injection molder specializing in medical, aerospace, and precision-molded components with a full-service engineering-to-production model. Comparable to Kaysun on regulated-industry certification stack and complex, low-volume parts.
- Mar-Bal: Diversified custom plastics and composites manufacturer with engineering services serving appliance, industrial, and transportation OEMs. Comparable to Kaysun on multi-vertical custom molding with strong engineering and value-added services.
- MRPC: Custom contract manufacturer of elastomers, silicones, and thermoplastics serving medical, industrial, and consumer OEMs with in-house tooling, molding, and assembly. Comparable to Kaysun on custom-molded-part manufacturing for regulated customers, particularly where insert and overmolded multi-material assemblies are involved.
Broad incumbents
- Helion Plastics: Larger diversified plastics manufacturer formed from Phillips Plastics and Trilogy Plastics, serving medical, automotive, defense, and industrial customers globally. Comparable on regulated verticals and broad full-service molding capabilities, but at materially greater scale.
Emerging players
- Protolabs: Digital on-demand manufacturer offering rapid-turn injection molding alongside CNC, sheet metal, and 3D printing. Overlaps with Kaysun on custom injection molding but competes primarily on speed and self-service quoting rather than full-service engineering partnerships.
- Fictiv: Digital manufacturing platform providing custom injection molding and CNC machining through a curated supplier network. Comparable on custom injection molding output but competes via platform orchestration rather than owned-and-operated factories like Kaysun.
Others
- Jabil: Global contract manufacturer with substantial plastics injection molding, tooling, and assembly operations across medical, automotive, and consumer. Overlaps with Kaysun on precision molding for regulated OEMs but operates at vastly larger scale and across multiple manufacturing processes.
Market position
Strengths5 records
Weaknesses5 records
Competitive moat5 records
Key risks6 records
Key highlights7 records
Customer concentration
Kaysun Corporation social profiles
Digital presenceKaysun Corporation financial estimates
Financial estimateRevenue estimate
Valuation estimate
Kaysun Corporation leadership team
Management profileNumber of profiles
Profiles6 records
Kaysun Corporation funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Kaysun Corporation M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Kaysun Corporation
What does Kaysun Corporation do?
Kaysun Corporation provides custom injection molding services for highly engineered, complex plastic parts serving medical, automotive, industrial, consumer, and defense OEMs. Offerings are delivered as a vertically integrated full-service model that combines in-house engineering support (DfM analysis, material selection, metal-to-plastic conversion), tool design and build, scientific and precision molding (including overmolding and insert molding), value-added secondary operations, and an in-house Quality Lab.
Is Kaysun Corporation a public or private company?
Kaysun Corporation is a private company. It is classified as founder individual operated bootstrapped and is currently operating.
When was Kaysun Corporation founded?
Kaysun Corporation was founded in 1946. It employs 251 to 500 people.
Where is Kaysun Corporation based?
Kaysun Corporation is headquartered in Manitowoc, United States, in the North America region.
How does Kaysun Corporation make money?
Three revenue lines are on record. Custom Injection Molding Services are the primary driver. The others are engineering & Professional Services and value-Added Services.
Who are Kaysun Corporation's main competitors?
Direct peers on record are EVCO Plastics, Tessy Plastics, PTI Engineered Plastics, Plastikos, Mar-Bal and MRPC. Helion Plastics is listed as a broad incumbent. Emerging players are Protolabs and Fictiv. Jabil is listed as an others.
Does Kaysun Corporation have an API?
No public API is recorded for Kaysun Corporation.
What industry is Kaysun Corporation in?
Kaysun Corporation's product category is Custom Plastic Injection Molding. Its primary akta.pro industry code is IMANAFAJ, Custom Injection Molding & Contract Manufacturing (Job Shops/CMs). Its NAICS code is 333511.