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Bi-Material Manufacturing Expertise Redefining Insert and Overmolding

Layana Company: Bi-Material Manufacturing Expertise Redefining Insert and Overmolding

In the ever-evolving landscape of precision manufacturing, Layana Company has positioned itself as a pioneering force through its unrivaled bi-material expertise. By seamlessly integrating the strengths of plastic injection molding and precision metal stamping under one roof, Layana delivers state-of-the-art solutions that power industries ranging from automotive and power electronics to medical and industrial automation. With a foundation rooted in total engineering solutions and sustainability, Layana offers a comprehensive suite of services, including in-house tooling design and development, a dedicated industrial-automation engineering team, and advanced overmolding and in-mold assembly capabilities.

 

Molten plastic merges with a metal coil, demonstrating insert molding or overmolding, with two sensors encapsulated in plastic.

 

Mastering Bi-Material Synergy: Plastic Injection Meets Metal Stamping

Layana’s manufacturing philosophy centers on bi-material innovation, combining the structural benefits of metal inserts with the design flexibility of engineered plastics. By managing both materials in-house, Layana reduces lead times, avoids supplier miscommunication, and expands design freedom. This expertise enables precise encapsulation of metal components—such as leadframes, terminals, and busbars—with high-performance resins, producing compact, reliable parts for power electronics, automotive, and medical applications. Layana’s in-mold assembly further integrates pre-molded components, creating complex, fully assembled solutions within the mold.

 

Layana’s bi-material manufacturing capabilities, featuring a sequence of processes including precision plastic injection molding, progressive die metal stamping, overmolding, insert molding and automated assembly.

 

In-Mold Assembly: The Evolution of Smart Manufacturing

In-mold assembly (IMA) is an advanced integration technique in which components are assembled directly within the mold during the injection cycle. By embedding metal inserts—such as terminals or leadframes—into the pre-mold and second shot, Layana eliminates manual assembly steps while delivering multiple benefits:

  • Improved structural and electrical integrity
  • Reduced lead time and labor costs
  • Higher dimensional accuracy
  • Miniaturization and weight reduction
  • Superior environmental sealing
  • Vibration-damping

IMA is critical for next-generation EV applications, power-control units, and smart-sensor systems. Leading EV manufacturers already trust Layana as a key partner for developing new automotive modules using this method.

 

Scientific Molding & DFM Integration for Precision and Reliability

Layana employs a scientific molding methodology that combines real-time process control with data-driven optimization across fill, pack, hold, and cooling phases. Integrated Design-for-Manufacturability (DFM) analysis and mold-flow simulations minimize defects—such as warpage, voids, short shots, and flashing—ensuring every component meets stringent dimensional and functional specifications.

 

Precision components created through premold + overmolding processes: sensor housings, connector assemblies, power-module enclosures, and a plastic accelerator pedal—each combining metal inserts and engineered plastics.

 

Overmolding & Insert Molding: Pioneering Beyond Prior Excellence

Layana’s overmolding solutions demonstrate mastery in multi-material integration—including single-shot, two-shot (2K), and pre-mold + overmold processes—enabling ergonomic surfaces, vibration-damping seals, and protective coatings in a single molded assembly. Reinforced-nylon EV charge ports, for example, achieve lightweight durability, water resistance, and structural integrity. Insert molding embeds precision-stamped metal components—such as power-module terminals, sensor pins, busbars, and heat-dissipating substrates—produced in-house with tight-tolerance progressive dies that lock metal securely into plastic during injection.

 

Layana’s in-mold assembly for NACS and CCS2 EV charge ports, combining premolding and overmolding to create high-performance components.

 

In-House Tooling Development and Rapid Prototyping to Mass Production

Layana’s in-house tooling shops provide full control over mold design, fabrication, maintenance, and modification—significantly reducing development cycles and enhancing manufacturing agility. Tooling capabilities include:

  • Precision progressive and transfer dies for inserts
  • High-productivity, tight-tolerance plastic injection molds
  • Custom inserts, hot runners, and gate designs
  • Mold-flow and DFM support to eliminate development-failure risk

Rapid prototyping is streamlined, allowing customers to test functional samples within days.

 

In-Mold Assembly Real-World Applications & OEM Trust

Layana’s bi-material approach is trusted by global OEMs across diverse sectors:

  • Automotive: EV charge ports, accelerator/braking pedals, MAP, throttle-position sensors, camshaft sensors, and more
  • Industrial Automation: Control-module housings, machine foot pedals, power-module housings, etc.
  • Consumer Electronics: Smart door locks, LED assemblies, sensor housings, etc.
  • Other: Medical equipment, biking, aerospace, and additional emerging markets

By uniting design, tooling, and production under one roof, Layana accelerates the delivery of next-generation components while ensuring unmatched quality and flexibility.

 

Certified Quality and Sustainability

Layana’s commitment to excellence is validated by globally recognized certifications:

 

 

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