@article{60210,
  abstract     = {{<jats:p>Currently, the need for resource efficiency and CO2 reduction is growing in industrial production, particularly in the automotive sector. To address this, the industry is focusing on lightweight components that reduce weight without compromising mechanical properties, which are essential for passenger safety. Hybrid designs offer an effective solution by combining weight reduction with improved mechanical performance and functional integration. This study focuses on a one-step manufacturing process that integrates forming and bonding of hybrid systems using compression molding. This approach reduces production time and costs compared to traditional methods. Conventional Post-Mold Assembly (PMA) processes require two separate steps to combine fiber-reinforced plastic (FRP) structures with metal components. In contrast, the novel In-Mold Assembly (IMA) process developed in this study combines forming and bonding in a single step. In the IMA process, glass-mat-reinforced thermoplastic (GMT) is simultaneously formed and bonded between two metal belts during compression molding. The GMT core provides stiffening and load transmission between the metal belts, which handle tensile and compressive stresses. This method allows to produce hybrid structures with optimized material distribution for load-bearing and functional performance. The process was validated by producing a lightweight hybrid brake pedal. Demonstrating its potential for efficient and sustainable automotive production, the developed hybrid brake pedal achieved a 35% weight reduction compared to the steel reference while maintaining mechanical performance under quasi-static loading</jats:p>}},
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Lückenkötter, Julian Janick Stefan and Tröster, Thomas and Marten, Thorsten}},
  issn         = {{2073-4360}},
  journal      = {{Polymers}},
  number       = {{12}},
  publisher    = {{MDPI AG}},
  title        = {{{Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly}}},
  doi          = {{10.3390/polym17121644}},
  volume       = {{17}},
  year         = {{2025}},
}

@phdthesis{50448,
  abstract     = {{Hybridstrukturen bieten bei Anwendungen mit Biegebeanspruchung ein großes Leichtbaupotenzial, erfordern jedoch komplexe und zum Teil mehrschrittige Fertigungsverfahren. In dieser Arbeit wird ein Verfahren entwickelt, das auf Basis des Fließpressprozesses biegebelastbare Hybridbalken in einem Schritt herstellt. Dazu wird ein Versuchsträger entwickelt, der die Komplexität von Realbauteilen abbildet und für zerstörende sowie zerstörungsfreie Charakterisierungsmethoden geeignet ist. Der Versuchsträger besteht aus einer funktionalisierten Kernstruktur aus Glasfasermattenverstärktem Polypropylen und äußeren Metallgurten aus Stahl- und Aluminiumlegierungen, die mit einem Haftvermittlerfilm versehen sind. Anhand des Versuchsträgers wird ein Fließpresswerkzeug und eine instrumentierte Fertigungsanlage entwickelt, mit der die Hybridstrukturen prototypisch hergestellt werden. Zur Prozessoptimierung wird die Verbindung mechanisch und optisch auf Probenebene analysiert. Weiterhin erfolgen Bauteiluntersuchungen anhand von Dreipunktbiegetests, mit denen das strukturelle Verhalten der Hybridbalken charakterisiert wird. Es wird festgestellt, dass sich mit dem einstufigen Fließpressverfahren sehr gute Verbundfestigkeiten erzielen lassen. Die Temperatur- und Druckführung weisen dabei einen großen Einfluss auf das Ergebnis auf. Anhand der Bauteiluntersuchungen wird bestätigt, dass mit dem entwickelten Verfahren Hybridbalken in nur einem Schritt gefertigt werden können, die vergleichbare mechanische Eigenschaften zu Hybridstrukturkonzepten aus mehrschrittigen Fertigungsverfahren aufweisen.}},
  author       = {{Stallmeister, Tim}},
  title        = {{{Verfahrensentwicklung zur einstufigen Herstellung von biegebelastbaren Hybridstrukturen im Fließpressprozess}}},
  doi          = {{10.17619/UNIPB/1-1670}},
  year         = {{2023}},
}

@inproceedings{45831,
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Lückenkötter, Julian and Tröster, Thomas}},
  keywords     = {{Compression Molding, Glass Mat Thermoplastics, Hybrid Brake Pedal}},
  location     = {{Trondheim, Norway }},
  title        = {{{In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding}}},
  year         = {{2023}},
}

@inproceedings{44154,
  abstract     = {{<jats:p>Abstract. Due to an increasing volume of shipments, there is a significant need for more delivery vehicles. One approach to reduce the associated increase in carbon dioxide (CO2) emissions is a new light weight design approach involving the substitution of conventional materials with glass fiber mat-reinforced thermoplastics (GMT) based on polypropylene (PP). The application of GMT by compression molding is a widely used process in the automotive industry. However, application in the commercial vehicle sector requires much larger dimensions, making it necessary to clarify whether the manufacturing process and material are suitable for semi-structural applications on this scale. To find this out, two replacement geometries are abstracted in this study and manufactured by varying the main manufacturing parameters. The feasibility can be demonstrated by recording and analyzing the resulting process variables and measuring the formed fiber distribution. At the end of the paper, recommendations are given for the production of GMT structures on the scale of commercial vehicles. </jats:p>}},
  author       = {{Lückenkötter, Julian and Leimbach, J.P. and Stallmeister, Tim and Marten, Thorsten and Tröster, Thomas}},
  booktitle    = {{Materials Research Proceedings}},
  issn         = {{978-1-64490-247-9}},
  keywords     = {{Compression Molding, Fiber Content, Process Development, Lightweight Design}},
  location     = {{Krakow, Poland}},
  pages        = {{249--258}},
  publisher    = {{Materials Research Forum LLC}},
  title        = {{{Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector}}},
  doi          = {{10.21741/9781644902479-27}},
  volume       = {{28}},
  year         = {{2023}},
}

@article{32869,
  abstract     = {{<jats:p>The further development of in-mold-assembly (IMA) technologies for structural hybrid components is of great importance for increasing the economic efficiency and thus the application potential. This paper presents an innovative IMA process concept for the manufacturing of bending loaded hybrid components consisting of two outer metal belts and an inner core structure made of glass mat reinforced thermoplastic (GMT). In this process, the core structure, which is provided with stiffening ribs and functional elements, is formed and joined to two metal belts in one single step. For experimental validation of the concept, the development of a prototypic molding tool and the manufacturing of hybrid beams including process parameters are described. Three-point bending tests and optical measurement technologies are used to characterize the failure behavior and mechanical properties of the produced hybrid beams. It was found that the innovative IMA process enables the manufacturing of hybrid components with high energy absorption and low weight in one step. The mass-specific energy absorption is increased by 693 % compared to pure GMT beams.</jats:p>}},
  author       = {{Stallmeister, Tim and Tröster, Thomas}},
  issn         = {{1662-9795}},
  journal      = {{Key Engineering Materials}},
  keywords     = {{Mechanical Engineering, Mechanics of Materials, General Materials Science}},
  pages        = {{1457--1467}},
  publisher    = {{Trans Tech Publications, Ltd.}},
  title        = {{{In-Mold-Assembly of Hybrid Bending Structures by Compression Molding}}},
  doi          = {{10.4028/p-5fxp53}},
  volume       = {{926}},
  year         = {{2022}},
}

@inproceedings{26994,
  author       = {{Stallmeister, Tim and Martin, Sven and Marten, Thorsten and Tröster, Thomas}},
  location     = {{Bad Nauheim}},
  title        = {{{Experimental investigation on lightweight potentials of fiber-metal-laminates for automotive battery cases}}},
  year         = {{2021}},
}

@inproceedings{27417,
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Wang, Zheng and Tröster, Thomas}},
  booktitle    = {{Hybrid 2020 Materials and Structures}},
  editor       = {{Hausmann, Joachim M and Siebert, Marc  and von Hehl, Axel and Weidenmann, Kay André}},
  location     = {{Digital}},
  pages        = {{167--172}},
  title        = {{{MANUFACTURING OF HYBRID COMPONENTS BY VARTM-PROCESS USING NEW SEALING TECHNIQUE DEVELOPED}}},
  year         = {{2020}},
}

@inproceedings{16032,
  author       = {{Stallmeister, Tim and Chalicheemalapalli Jayasankar, Deviprasad and Wang, Z. and Tröster, Thomas}},
  isbn         = {{9781925627220}},
  location     = {{Melbourne }},
  title        = {{{Self-sealing tool concept for RTM-processes}}},
  year         = {{2019}},
}

@inproceedings{16033,
  author       = {{Stallmeister, Tim and Chalicheemalapalli Jayasankar, Deviprasad and Wang, Z. and Tröster, Thomas}},
  location     = {{Neu-Ulm}},
  title        = {{{Selbstabdichtendes Werkzeugkonzept für RTM-Prozesse}}},
  year         = {{2019}},
}