Development Process for the design and structural engineering of thermally direct joined plastic-metal hybrid joints

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In recent years, multi-material design has proved to be a consistent advancement of all previous lightweight design strategies. Due to the right material being used in the right place, according to load and application, new ways of saving weight are emerging. Reliable joining processes are necessary for the implementation of multi-material lightweight design on an industrial scale. In addition to mechanical joining methods, which are not always suitable due to a punctual load application, bonding methods are state of the art, which have very long process times due to a complex surface preparation and curing times.
Approaches for laser-based joining of thermoplastics and metals have been developed in recent years. In the research-project "TailoredJoints" these promising and industry-relevant methods will be further improved. In the future, they shall enable the use of customized, laser-based joining of fiber composites with thermoplastic matrix and metals on a large scale suitable for mass production.


Research objectives

The aim of the project is to reduce the weight compared to conventional joining techniques by eliminating additional components, saving process steps and manufacturing costs by process-integrated joining, building up an improved process understanding through simulation, and achieving a 100% recycling rate of the individual components. Finally, the results will be transferred to a demonstrator part for validation.
Reliable joining processes enable a cost-effective production of hybrid components suitable for high volume series applications. The project thus supports the implementation of multi-material lightweight design in various sectors and the strengthening of industrial competitiveness through resource-saving hybrid component production.


Research and project partners

  • Gubesch Thermoforming GmbH
  • EDAG Engineering GmbH
  • Faurecia Autositze GmbH
  • Fraunhofer-Institut für Lasertechnik (ILT)
  • Institut für Maschinenelemente und Systementwicklung der RWTH Aachen

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Promoted by

Federal Minestry of Education and Research

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Project sponsor

Forschungszentrum Jülich GmbH