Kaysun Corporation

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.

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

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

• Custom injection molding
• Scientific molding services
• Plastic component manufacturing
• Injection mold tooling
• Medical device molding

Headquarters

HQ city

Manitowoc

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Infrastructure, Technology or R&D, Supply Chain, Marketing or Sales

Revenue model

1. 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.
2. 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.
3. 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

Go-to-market motion1 record

Distribution channels1 record

Marketing channels9 records

Core 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

Named customers6 records

Segments5 records

Ideal customer profiles4 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

Four partnerships are on record, tiered core.

• SodickcoreTechnology or Integration · 1 January 2007Kaysun'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 EnergycoreStrategic or Co-development PartnerPartnership 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.
• ToyocoreTechnology or IntegrationToyo 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 MaffeicoreTechnology or IntegrationKraus 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

Direct 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

• Xx.com/kaysuncorp
• YouTubeyoutube.com/@KaysunCorporation
• Facebookfacebook.com/KaysunCorp
• LinkedInlinkedin.com/company/kaysun-corporation

Revenue estimate

Valuation estimate

Number of profiles

Profiles6 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Kaysun Corporation