PROCESSES

Innovative processes and technologies

The Leva Group stands out for its flexibility and speed in designing processes that enable the creation of high-quality finished products, which can be produced in large quantities in short timeframes. We invest in the development of innovative processes and technologies to offer cutting-edge solutions that meet market needs.

High Frequency Welding

High-frequency (HF) welding occurs by melting the material through the application of HF energy in the form of an electromagnetic field, usually between two metal electrodes, plates, or molds. This process, combined with the pressure exerted on the material surfaces, produces a strong, uniform, and high-quality weld. It also allows for the creation of complex geometric shapes such as quilting.

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Ultrasonic welding

The welding process uses a safe and efficient technique, suitable for multiple production processes. This method ensures the safety of operators and the environment. With a cycle time that can drop below one second, it is widely used in industrial production lines. It eliminates any operator-related variability, ensuring consistent and superior quality over time.

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Injection molding

In order to verticalize the entire production chain, a department specialized in plastic injection molding was established for the manufacture of components of various shapes and sizes.

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Weaving

We create elastic and inelastic meshes of various sizes and with custom textures, according to our customers' specific needs. 3D weaving can be achieved using a variety of materials such as PP, PA, glass fiber, PES, and more.

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Thermoforming

Thermoforming is a process that allows for the mass production of components of various shapes and sizes while maintaining modern aesthetic designs in line with current trends. We can pressure-form thermoplastic composites by heating the component, achieving high standards of quality and precision.

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Numerically controlled cutting

Automatic nesting and cutting processes optimize the processing of genuine leather, faux leather, plastic, Teflon, and plexiglass, with significantly reduced processing times and precise repeatability. Our computer system, leveraging the collected data, determines the best nesting of shapes and optimizes material usage, significantly reducing raw material costs thanks to the easy elimination of any defects. This process ensures excellent finished product quality.

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Die cutting

Die cutting allows us to cut flat and thin materials into specific and extremely precise shapes. Our flexibility also extends to our ability to make custom cuts of various types and sizes, ranging from a minimum of 150 mm to a maximum of 1500 mm, depending on the customer's needs.

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Sewing

We specialize in sewing all types of fabrics, PVC, faux leather, bonded materials, and particularly high-quality materials such as genuine leather and Alcantara. A department equipped with the finest sewing machines (linear and double, flatbed and arm), combined with the skilled operators, gives our industrial capacity a charm, precision, and artisanal attention to every detail. Furthermore, an automated sewing system allows us to industrialize the process and reduce time and costs when producing large quantities.

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Gluing

Our expertise and experience in numerous gluing techniques, both manual and automated, allow us to handle all gluing needs for any type of material. Hot melt glue is applied using a roller coater; water- or solvent-based glues are applied manually or automatically (via a collaborative robot). To ensure better glue adhesion, plasma pretreatment is performed, which is the key technology for removing all impurities and activating the surfaces of almost all types of materials: plastic, metal, glass, fabrics, and composites.

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Uphostery

We have a long history of specializing in all types of upholstery. Our craftsmen combine advanced technical expertise, precise craftsmanship, and flexible creativity to create automotive interiors that not only meet rigorous functional standards but also excel aesthetically. Thanks to our automated turning system, we ensure perfect adhesion of the stitched lining to the plastic part. This process significantly optimizes the production times of the finished product.

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