A method of forming a folded overlay ply in a tire assembly comprising the steps of: (i) providing a tire sub-assembly comprising two beads, at least one carcass ply wrapped around each bead and at least one belt ply positioned on top of the carcass ply, (ii) placing a first rubber sheet on top of the upper belt ply, (iii) positioning an overlay cord on top of the first rubber sheet a predetermined distance from the first end of the region to be covered by the overlay, (iv) wrapping the overlay cord at the desired angle, orientation and deposition rate while traversing the cord towards the first end of the region to be covered by the overlay so as to form the base of the first fold in the overlay, (v) placing a second rubber sheet on top of the deposited overlay cord section formed in step (iv), (vi) wrapping the overlay cord at the desired angle and deposition rate in an orientation opposite to that of the orientation of the cord in the base of the first fold while traversing the cord towards the second end of the region to be covered by the overlay so as to complete the first fold an form the base of the second fold, (vii) placing a third rubber sheet on top of the deposited overlay cord section formed in step (vi), (viii) wrapping the overlay cord at the desired angle and deposition rate in an orientation similar to that of the orientation of the cord in the base of the first fold while traversing the cord a predetermined distance towards the first end of the region to be covered by the overlay so as to complete the second fold, and (ix) placing a fourth rubber sheet on top of the deposited overlay cord section formed in step (viii). (i) providing a tire sub-assembly comprising two beads, at least one carcass ply wrapped around each bead and at least one belt ply positioned on top of the carcass ply, (ii) placing a first rubber sheet on top of the upper belt ply, (iii) positioning an overlay cord on top of the first rubber sheet a predetermined distance from the first end of the region to be covered by the overlay, (iv) wrapping the overlay cord at the desired angle, orientation and deposition rate while traversing the cord towards the first end of the region to be covered by the overlay so as to form the base of the first fold in the overlay, (v) placing a second rubber sheet on top of the deposited overlay cord section formed in step (iv), (vi) wrapping the overlay cord at the desired angle and deposition rate in an orientation opposite to that of the orientation of the cord in the base of the first fold while traversing the cord towards the second end of the region to be covered by the overlay so as to complete the first fold an form the base of the second fold, (vii) placing a third rubber sheet on top of the deposited overlay cord section formed in step (vi), (viii) wrapping the overlay cord at the desired angle and deposition rate in an orientation similar to that of the orientation of the cord in the base of the first fold while traversing the cord a predetermined distance towards the first end of the region to be covered by the overlay so as to complete the second fold, and (ix) placing a fourth rubber sheet on top of the deposited overlay cord section formed in step (viii).