Combined Deep Drawing and Compression Molding Process for Manufacturing Metal-Plastic Hybrid Components Using VESTAMELT ® Hylink

The objective, as clearly stated, is to develop high-performance manufacturing methods that will reduce the weight of metallic chassis components. The result is approximately 20 percent weight savings achieved in two different automotive control arms. And all of this is achieved through adhesive bonding between metal and long-fiber-reinforced thermoplastic (LFT) via VESTAMELT® Hylink adhesion promoter. A versatile manufacturing process was employed for the simultaneous creation and molding of fiber-reinforced plastics with metal sheets.

Composite Compression Molding Process

Metal and plastic hybrid component parts are typically bonded through friction or with the aid of elements such as screws and rivets, or through multi-component molding and insert molding. The challenge here is to develop a new manufacturing method that encompasses the creation of metal sheets while taking into account the variable wall thickness distribution of reinforcing ribs and fiber-reinforced plastics, and the molding of long-fiber-reinforced thermoplastics (BMBF: Versatile 02PN2081). In connection with this process, an adhesive bonding technology as provided by VESTAMELT® Hylink is required. For example, polyamide 6, polyamide 610, and 40 percent long glass fiber-reinforced polyamide 12 were used in a longitudinal control arm.