Development of a mechanical interlocking plastic/light-metal hybrid composite with a Class A surface

In lighting applications as in many other segments, the trend towards lightweight construction and increased functionality is making it increasingly necessary to combine disparate materials with one another in a single product. By combining the good thermal conductivity of die-cast components with the high surface quality of injection-moulded parts, it is possible to satisfy the stringent demands of LED technology. 

Research objective

The aim of this cooperation project is to develop a hybrid, amorphous thermoplastic/light-metal composite. The joining technology used for this is a quasi-full-area microscale laser structuring on the light-metal component. Through the back-moulding of the structured surface, the composite is produced during the moulding of the plastic. This high-strength material composite is resistant to changing temperatures and can also be optimised with regard to its media-proof characteristics. It can be used to produce functional, load-bearing components with decorative covering components in a single part, whereby build volume and weight as well as logistics and assembly costs can be significantly reduced through shorter process chains.

Project partners

Christoph Zimmermann, M.Sc.

Head of department Injection Moulding +49 241 80-93827