Metal-Plastic Hybrid Parts

Diehl Metal Applications (DMA) develops and manufactures custom metal-plastic hybrid parts for demanding electrical and mechatronic applications. Our solutions are used wherever the highest standards of precision, reliability, electrical connectivity, and functional integration are required— from sensor and actuator applications through electrification, battery systems, and power electronics to industrial automation solutions (Robotics & Automation).

By intelligently combining the electrical conductivity and mechanical stability of metal with the insulation and design possibilities of plastic, our hybrid components enable a high degree of functional integration. Multiple functions are combined into a single component, thereby reducing the number of parts, interfaces, and assembly effort. This saves installation space and weight, increases process reliability, and creates cost-effective solutions for complex applications.

With our expertise in insert molding, precision stamping, and plastic overmolding, we support our customers from development through global series production.

Broad Product Portfolio for Diverse Applications

Our metal-plastic hybrid parts are custom-designed to meet our customers’ requirements and are used worldwide in the automotive industry as well as in applications in industrial electronics, electrification, and industrial robotics:

Automotive & Industry Solutions

  • ADAS sensor housings for radar, ultrasonic, and other driver-assistance systems
  • Sensor housings and hybrid components for sensor and actuator systems (e.g., ABS/ESP, transmission control)
  • Overmolded housings for safety, thermal management, and header systems
  • Control unit and ECU components
  • Pump housings and fluidic modules

 

Electrification & Power Electronics

  • Cell contact and connection systems for battery systems and e-mobility applications
  • Overmolded connectors for reliable electrical connections
  • High-current connectors for high-performance applications
  • Components for power electronics
  • Busbars and other high-power components

 

Automation & Robotics

  • Hybrid components for industrial robotics and automated manufacturing systems
  • Electrical connection solutions for industrial electronics
  • Custom metal-plastic hybrid parts for demanding mechatronic applications

Technology & Manufacturing

Intelligent Hybrid Solutions for Demanding Applications

Modern electrical and mechatronic systems place ever-increasing demands on installation space, weight, electrical performance, and reliability. Metal-plastic hybrid parts offer decisive advantages over components made from a single material.

Through the intelligent combination of metal and plastic, hybrid components combine the high electrical conductivity and mechanical stability of metal with the insulation and design possibilities of plastic. At the same time, they enable a high degree of functional integration: Multiple functions that were previously distributed across various individual parts can be combined into a single component. This reduces the number of components, simplifies assembly, saves space and weight, and simultaneously increases process reliability and the cost-effectiveness of the overall system.

Whether sensor housings, actuators, overmolded connectors, high-current connectors, or components for battery systems, power electronics, and industrial robotics—our hybrid solutions lay the foundation for high-performance, future-proof products.

From development to series production

Every application has unique requirements in terms of function, material, and manufacturing process. That’s why we support our customers throughout the entire value chain—from the initial product concept through engineering and tooling to automated series production and quality assurance.

As early as the development phase, we optimize components in terms of functional integration, manufacturability, and cost-effectiveness. This results in custom-designed hybrid components that are optimally tailored to the respective application and meet the highest standards for quality, efficiency, and suitability for mass production.

High-Precision Insert Molding Technology

At the heart of our manufacturing process is modern insert molding technology. In this process, precision metal components are directly overmolded with plastic and permanently bonded to form a highly integrated hybrid component.

This technology enables compact designs, reliable electrical connections, and the integration of multiple functions into a single component. It is suitable for both delicate sensor housings and actuators as well as for demanding applications in electrification, power electronics, battery systems, and high-current technology.

Flexible Manufacturing System & One-Stop-Shop

Flexible manufacturing system—everything from a single source

With our modular plant concept (MAB), we flexibly adapt manufacturing processes to our customers’ requirements—from material selection and component geometry to the degree of automation.

All process steps are integrated within a seamless manufacturing solution:

  • Engineering and toolmaking
  • Precision stamping technology
  • Insert molding and plastic overmolding
  • In-line inspection and quality assurance
  • Cleaning and laser marking
  • Assembly and Packaging

Thanks to this one-stop-shop approach, our customers benefit from short development times, high process reliability, reproducible quality, and cost-effective series production.

Would you like to reduce assembly complexity? Would you like to integrate multiple functions into a single component?

Metal-plastic hybrid parts offer decisive advantages over conventional metal or plastic components:

  • High functional integration by combining multiple functions into a single component
  • Fewer individual parts and reduced interfaces
  • Less assembly effort and lower system costs
  • Compact and weight-optimized designs
  • High electrical conductivity combined with reliable insulation
  • High precision and process reliability even with complex geometries
  • Scalable manufacturing from prototypes to high-volume production
  • Customized solutions for the automotive industry, electrification, battery systems, power electronics, industrial electronics, and industrial robotics

Learn more about the technology, manufacturing processes, and quality methods for our hybrid parts here:

Overmolding & Assembly Technology

  • Integrated Value Creation

    DMA offers a fully integrated manufacturing chain from a single source—our one-stop shop includes:

    • Precision stamped parts as the basis for hybrid solutions View the precision stamped parts portfolio
    • Surface finishing (e.g., nickel, silver, tin, gold, Advanced Indium/AgSn) Coating Technology
    • Insert Molding for Metal-Plastic Composite Parts
    • Assembly & Packaging for Finished Assemblies
    • Process Monitoring & Traceability for Maximum Stability
  • Quality & Automotive Standards

    Whether you have specific component requirements or are pursuing strategic product development—our experts will guide you from the initial idea through to series production.

    DMA products meet the highest quality standards and undergo comprehensive testing—from engineering through simulations and in-line inspection to series production approval. Our production processes comply with the relevant ISO 9001 and IATF 16949 standards, which is essential, particularly for automotive and safety-critical applications.

  • Your Partner: Diehl Metal Applications

    Diehl Metal Applications combines comprehensive expertise in the development and manufacturing of sophisticated metal and hybrid solutions. From precision stamped parts to metal-plastic hybrid parts and complex assemblies, the company produces innovative components for automotive, electrical, and industrial applications.

    Learn more about DMA’s technologies, manufacturing capabilities, and comprehensive service portfolio—and discover how integrated processes lead to efficient and future-oriented solutions.

    Everything about Diehl Metal Applications

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