overmoulding / stamping
hybrid components / contact elements

An important area of expertise in the company is connectivity and the connection between plastic and metal. The product applications are extensive, such as socket housings, connectors, adapters or charging plugs for electromobility; in everyday life or at work – we use these small aids all the time.

Keyword electromobility: The leading OEMs have been working on the trend reversal towards e-mobility for several years. According to forecasts, every fourth car produced in Germany will be a fully electric vehicle by 2026. The charging infrastructure is being increasingly expanded worldwide. This means that the demand for socket-plug connections will increase dramatically. But the demand for sensor technology is also increasing enormously! The more technology, the greater the number of sensors, such as force, torque, displacement, pressure or angle of rotation sensors. Vehicles are no longer primarily a means of transportation, but are increasingly becoming communication objects (networking of vehicles with each other, autonomous driving, W-Lan on board, etc.). There are interfaces everywhere (GPS, USB, WIFI …). This enormous increase in electrical technical aids is also linked to the need for overmolded parts, so-called plastic-metal hybrid parts. Small metal contacts or stamped grids have to be combined in a plastic housing.  

ZEIBINA produces various applications of plastic-metal hybrid parts, mainly for the automotive industry. For example, metal pins with a cross-section of 0.6mm x 0.6mm are punched on the belt and fully automatically configured to the bending angle and overmolded to ensure the customer’s plug-in connection to the vehicle in the torque sensor assembly. Another well-known project is the Smart Trunk Opener from Daimler. This assembly is installed under the rear bumper to enable contactless opening of the trunk lid. This application is manufactured with high precision at ZEIBINA.

Apart from the electroplating of the metal parts, the process takes place under one roof at ZEIBINA. The pins and other stamped parts are stamped in-house in quantities of millions, then optionally coated with tin, silver or gold and finally overmolded with plastic to form the finished component. Other processes, such as the welding of pressure compensation membranes, can be integrated at the customer’s request. ZEIBINA’s fully automated systems enable high production volumes, competitiveness on the international market and a high level of quality in terms of accuracy and reproducibility. We currently have 8 vertical injection molding machines with freely programmable robot systems in use for this production area. The production lines are camera-monitored and each part is subjected to a continuity and high-voltage test. At the customer’s request, we are also happy to take care of further assembly – right through to the finished assembly group.