Processes
Leva Group stands out for its ability to be flexible and quick in designing processes that allow the creation of high-quality finished products, which can be produced in large quantities in a short time. We invest in the development of innovative processes and technologies to offer cutting-edge solutions that meet market demands.
High-frequency welding (HF) occurs through the fusion of material by applying 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’s surfaces, generates a robust, uniform, and high-quality weld. Additionally, it allows for the creation of complex geometric shapes such as quilting. The most commonly used materials are PVC and Alcantara, both in single layers and laminated.
In the welding process, a safe and efficient technique is employed, 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-induced variability, ensuring consistent and superior quality over time.
To verticalize the entire production chain, a specialized department for plastic injection molding has been established to manufacture components of various shapes and sizes.
We create elastic and inelastic nets of various sizes with customized patterns to meet specific customer needs. 3D weaving can be achieved using a variety of materials such as PP, PA, glass fibers, PES, and others.
Thermoforming is a process that allows the mass production of components in various shapes and sizes while maintaining modern aesthetic designs in line with current trends. We are capable of shaping thermoplastic composites under heat and pressure to achieve high standards of quality and precision.
The processes of nesting and automatic cutting optimize the processing of real leather, simil leather, plastic, teflon, and plexiglass with greatly reduced work times and precise repeatability. Leveraging collected data, our computer system determines the optimal nesting of shapes and optimizes material usage, significantly reducing raw material costs by easily eliminating potential defects. This process ensures excellent quality of the finished product.
Die-cutting allows cutting flat and thin materials into specific and extremely precise shapes. Our flexibility is evident in our ability to perform customized cuts of various types and sizes, ranging from a minimum of 150 mm to a maximum of 1500 mm, according to customer needs.
We specialize in sewing various types of fabrics, PVC, simil leather, laminated materials, and high- quality materials such as real leather and Alcantara. Our department is equipped with the best sewing machines (single and double needle, flatbed and arm machines), combined with skilled operators, providing industrial capability with charm, precision, and meticulous craftsmanship in every detail. Additionally, an automated sewing system enables industrialization of the process, reducing time and costs in the production of large quantities of items.
Our expertise and experience in numerous gluing techniques, both manual and automatic, allow us to manage all gluing requirements for any type of material. Hot glue is applied using a Roller Coater; water-based or solvent-based adhesives are applied through either manual or automatic spraying (collaborative robot). To ensure better adhesion of the glue, plasma pretreatment is carried out, which is the key technology for eliminating any impurities and for activating the surfaces of almost all types of materials: plastics, metals and glass, fabrics, and composites.
We have historically specialized in all upholstery processes. Our craftsmen combine advanced technical skills, artisanal precision, and flexible creativity to create automotive interiors that not only meet strict functional standards but also excel aesthetically. Thanks to our automated edging system, we ensure the perfect adherence of the sewn cover to the plastic part. This process significantly optimizes the production times of the finished product.