Universeal

The original Universeal product was manufactured using two separately molded components that were later assembled using ultrasonic welding.

This process presented several limitations:

• Variable reliability: an imperfect weld could lead to part separation.
• Risks to the quality and integrity of the final product.
• Multiple manufacturing steps and manual handling.
• A process that was difficult to stabilize over the long term.

The objective was therefore to develop a more robust and automated manufacturing process while preserving the product’s distinctive two-color appearance.

Our Solution

We developed an integrated manufacturing approach based on a two-step overmolding process.

Key actions included:

• Molding a base substrate followed by overmolding with a second colored material.
• Integrating color coding directly into the mold, eliminating the aesthetic assembly step.
• Designing a precise internal geometry to preserve the space required for the later pin assembly.

This approach transformed a fragile assembly process into a robust and integrated manufacturing solution.

The Result

The new process combines molding, identification, and assembly within an automated production flow:

• Laser engraving of the serial number between plastic layers, protected from wear.
• Automatic pin assembly directly at the molding cell output.
• Continuous production without manual handling.

Production is now more stable, more predictable, and easier to operate.