@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}},
}

@inproceedings{48586,
  author       = {{Lückenkötter, Julian and Aydin, Simon and Marten, Thorsten and Tröster, Thomas}},
  location     = {{Belfast}},
  title        = {{{Analysis and Optimization of Joint Formation in Hybrid Compression Molding}}},
  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}},
}