Page 42 - Research Report 2021 - Institut für Leichtbau und Kunststofftechnik

hypro

Holistic implementation of hybrid design in
series production

Adhesively bonded thermoplastic composite metal structures offer a high po- Period
tential for weight reduction, especially for geometrically complex and highly 01.05.2020 – 31.10.2022
loaded lightweight structures. However, to ensure a resistant adhesion be-
tween the metal insert, thermoplastic composites (TPC) and injection mould- Project management
ing compound, the metal surface must be carefully pre-treated. Therefore, the Prof. Dr.-Ing. habil. Maik Gude
production technology for these hybrid structures is currently not competitive
and is not yet implemented on an industrial scale. Contact
Dr.-Ing. Robert Kupfer
The BMBF project hypro aims to close this gap and to build up a comprehen- Alexander Liebsch
sive understanding of thermoplastic composite metal structures. For this pur-
pose, a combined physical and virtual process chain is developed. The core Project partners
of this process chain is an injection molding technology in which deep-drawn • Consortium leadership:
metal inserts are combined with prefabricated TPC patches and overmolded Brose Fahrzeugteile SE & Co. KG

with fibre-reinforced plastic. To ensure a highly resilient bond between the • AUMO GmbH
plastic components and the metal insert, the metal surface is cleaned and • COBES GmbH
coated inline using plasma technology. During the whole process chain, the • FEP Fahrzeugelektrik Pirna GmbH
& Co. KG

component-specific process data are recorded and processed for compre- • GK Concept GmbH
hensive process studies. The combination of physical and simulation data • inpro Innovationsgesellschaft für
enables computationally based non-destructive inline quality assurance and fortgeschrittene Produktionssysteme
the prediction of component properties. in der Fahrzeugindustrie mbH
• Plasmatreat GmbH
• Symate GmbH
• Laboratory for material and joining
technology (LWF) at the Paderborn
University (UPB)

Funding

Generic hypro hybrid part: concept (left) and manufactured hybrid part (right). Federal Ministry of Education and
Research (BMBF)
Funding code: 03XP0284J

Managed by:

Projektträger Jülich (PTJ)

Automated hypro manufacturing cell.

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