[{"date_updated":"2026-03-20T08:44:36Z","oa":"1","volume":17,"author":[{"last_name":"Chalicheemalapalli Jayasankar","orcid":"https://orcid.org/ 0000-0002-3446-2444","full_name":"Chalicheemalapalli Jayasankar, Deviprasad","id":"49504","first_name":"Deviprasad"},{"first_name":"Tim","id":"45538","full_name":"Stallmeister, Tim","last_name":"Stallmeister"},{"last_name":"Lückenkötter","full_name":"Lückenkötter, Julian Janick Stefan","id":"45543","first_name":"Julian Janick Stefan"},{"first_name":"Thomas","last_name":"Tröster","full_name":"Tröster, Thomas","id":"553"},{"first_name":"Thorsten","orcid":"0009-0001-6433-7839","last_name":"Marten","id":"338","full_name":"Marten, Thorsten"}],"doi":"10.3390/polym17121644","main_file_link":[{"url":"https://www.mdpi.com/2073-4360/17/12/1644","open_access":"1"}],"publication_identifier":{"issn":["2073-4360"]},"publication_status":"published","intvolume":"        17","citation":{"ama":"Chalicheemalapalli Jayasankar D, Stallmeister T, Lückenkötter JJS, Tröster T, Marten T. Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly. <i>Polymers</i>. 2025;17(12). doi:<a href=\"https://doi.org/10.3390/polym17121644\">10.3390/polym17121644</a>","chicago":"Chalicheemalapalli Jayasankar, Deviprasad, Tim Stallmeister, Julian Janick Stefan Lückenkötter, Thomas Tröster, and Thorsten Marten. “Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly.” <i>Polymers</i> 17, no. 12 (2025). <a href=\"https://doi.org/10.3390/polym17121644\">https://doi.org/10.3390/polym17121644</a>.","ieee":"D. Chalicheemalapalli Jayasankar, T. Stallmeister, J. J. S. Lückenkötter, T. Tröster, and T. Marten, “Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly,” <i>Polymers</i>, vol. 17, no. 12, Art. no. 1644, 2025, doi: <a href=\"https://doi.org/10.3390/polym17121644\">10.3390/polym17121644</a>.","bibtex":"@article{Chalicheemalapalli Jayasankar_Stallmeister_Lückenkötter_Tröster_Marten_2025, title={Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly}, volume={17}, DOI={<a href=\"https://doi.org/10.3390/polym17121644\">10.3390/polym17121644</a>}, number={121644}, journal={Polymers}, publisher={MDPI AG}, author={Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Lückenkötter, Julian Janick Stefan and Tröster, Thomas and Marten, Thorsten}, year={2025} }","mla":"Chalicheemalapalli Jayasankar, Deviprasad, et al. “Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly.” <i>Polymers</i>, vol. 17, no. 12, 1644, MDPI AG, 2025, doi:<a href=\"https://doi.org/10.3390/polym17121644\">10.3390/polym17121644</a>.","short":"D. Chalicheemalapalli Jayasankar, T. Stallmeister, J.J.S. Lückenkötter, T. Tröster, T. Marten, Polymers 17 (2025).","apa":"Chalicheemalapalli Jayasankar, D., Stallmeister, T., Lückenkötter, J. J. S., Tröster, T., &#38; Marten, T. (2025). Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly. <i>Polymers</i>, <i>17</i>(12), Article 1644. <a href=\"https://doi.org/10.3390/polym17121644\">https://doi.org/10.3390/polym17121644</a>"},"_id":"60210","department":[{"_id":"9"},{"_id":"321"},{"_id":"149"}],"user_id":"49504","article_number":"1644","type":"journal_article","status":"public","publisher":"MDPI AG","date_created":"2025-06-15T20:16:14Z","title":"Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly","quality_controlled":"1","issue":"12","year":"2025","language":[{"iso":"eng"}],"publication":"Polymers","abstract":[{"lang":"eng","text":"<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>"}]},{"citation":{"bibtex":"@inproceedings{Lückenkötter_Aydin_Marten_Tröster_2023, title={Analysis and Optimization of Joint Formation in Hybrid Compression Molding}, author={Lückenkötter, Julian and Aydin, Simon and Marten, Thorsten and Tröster, Thomas}, year={2023} }","mla":"Lückenkötter, Julian, et al. <i>Analysis and Optimization of Joint Formation in Hybrid Compression Molding</i>. 2023.","short":"J. Lückenkötter, S. Aydin, T. Marten, T. Tröster, in: 2023.","apa":"Lückenkötter, J., Aydin, S., Marten, T., &#38; Tröster, T. (2023). <i>Analysis and Optimization of Joint Formation in Hybrid Compression Molding</i>. 23nd International Conference on Composite Materials (ICCM23 2023), Belfast.","ama":"Lückenkötter J, Aydin S, Marten T, Tröster T. Analysis and Optimization of Joint Formation in Hybrid Compression Molding. In: ; 2023.","chicago":"Lückenkötter, Julian, Simon Aydin, Thorsten Marten, and Thomas Tröster. “Analysis and Optimization of Joint Formation in Hybrid Compression Molding,” 2023.","ieee":"J. Lückenkötter, S. Aydin, T. Marten, and T. Tröster, “Analysis and Optimization of Joint Formation in Hybrid Compression Molding,” presented at the 23nd International Conference on Composite Materials (ICCM23 2023), Belfast, 2023."},"year":"2023","conference":{"start_date":"2023-07-31","name":"23nd International Conference on Composite Materials (ICCM23 2023)","location":"Belfast","end_date":"2023-08-04"},"title":"Analysis and Optimization of Joint Formation in Hybrid Compression Molding","date_created":"2023-11-02T08:29:45Z","author":[{"last_name":"Lückenkötter","full_name":"Lückenkötter, Julian","id":"45543","first_name":"Julian"},{"first_name":"Simon","last_name":"Aydin","full_name":"Aydin, Simon"},{"full_name":"Marten, Thorsten","id":"338","last_name":"Marten","first_name":"Thorsten"},{"full_name":"Tröster, Thomas","id":"553","last_name":"Tröster","first_name":"Thomas"}],"date_updated":"2023-11-02T08:30:43Z","status":"public","type":"conference","language":[{"iso":"eng"}],"user_id":"45543","department":[{"_id":"321"},{"_id":"9"},{"_id":"149"}],"_id":"48586"},{"author":[{"last_name":"Chalicheemalapalli Jayasankar","orcid":"https://orcid.org/ 0000-0002-3446-2444","id":"49504","full_name":"Chalicheemalapalli Jayasankar, Deviprasad","first_name":"Deviprasad"},{"first_name":"Tim","last_name":"Stallmeister","full_name":"Stallmeister, Tim","id":"45538"},{"last_name":"Lückenkötter","full_name":"Lückenkötter, Julian","id":"45543","first_name":"Julian"},{"last_name":"Tröster","id":"553","full_name":"Tröster, Thomas","first_name":"Thomas"}],"date_created":"2023-07-03T08:23:15Z","date_updated":"2024-03-26T09:19:44Z","conference":{"name":"5th International Conference on Light Materials - Science and Technology LightMAT 2023","start_date":"2023-06-21","end_date":"2023-06-23","location":"Trondheim, Norway "},"title":"In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding","has_accepted_license":"1","citation":{"ama":"Chalicheemalapalli Jayasankar D, Stallmeister T, Lückenkötter J, Tröster T. In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding. In: ; 2023.","ieee":"D. Chalicheemalapalli Jayasankar, T. Stallmeister, J. Lückenkötter, and T. Tröster, “In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding,” presented at the 5th International Conference on Light Materials - Science and Technology LightMAT 2023, Trondheim, Norway , 2023.","chicago":"Chalicheemalapalli Jayasankar, Deviprasad, Tim Stallmeister, Julian Lückenkötter, and Thomas Tröster. “In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding,” 2023.","mla":"Chalicheemalapalli Jayasankar, Deviprasad, et al. <i>In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding</i>. 2023.","bibtex":"@inproceedings{Chalicheemalapalli Jayasankar_Stallmeister_Lückenkötter_Tröster_2023, title={In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding}, author={Chalicheemalapalli Jayasankar, Deviprasad and Stallmeister, Tim and Lückenkötter, Julian and Tröster, Thomas}, year={2023} }","short":"D. Chalicheemalapalli Jayasankar, T. Stallmeister, J. Lückenkötter, T. Tröster, in: 2023.","apa":"Chalicheemalapalli Jayasankar, D., Stallmeister, T., Lückenkötter, J., &#38; Tröster, T. (2023). <i>In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding</i>. 5th International Conference on Light Materials - Science and Technology LightMAT 2023, Trondheim, Norway ."},"year":"2023","user_id":"49504","department":[{"_id":"9"},{"_id":"321"},{"_id":"149"}],"_id":"45831","language":[{"iso":"eng"}],"file_date_updated":"2023-07-03T08:15:04Z","ddc":["620"],"keyword":["Compression Molding","Glass Mat Thermoplastics","Hybrid Brake Pedal"],"type":"conference_abstract","file":[{"success":1,"relation":"main_file","content_type":"application/pdf","file_size":359467,"access_level":"closed","file_name":"LightMAT-2023_Extended Abstract.pdf","file_id":"45832","date_updated":"2023-07-03T08:15:04Z","creator":"dcj","date_created":"2023-07-03T08:15:04Z"}],"status":"public"},{"citation":{"bibtex":"@inproceedings{Lückenkötter_Leimbach_Stallmeister_Marten_Tröster_2023, title={Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector}, volume={28}, DOI={<a href=\"https://doi.org/10.21741/9781644902479-27\">10.21741/9781644902479-27</a>}, booktitle={Materials Research Proceedings}, publisher={Materials Research Forum LLC}, author={Lückenkötter, Julian and Leimbach, J.P. and Stallmeister, Tim and Marten, Thorsten and Tröster, Thomas}, year={2023}, pages={249–258} }","mla":"Lückenkötter, Julian, et al. “Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector.” <i>Materials Research Proceedings</i>, vol. 28, Materials Research Forum LLC, 2023, pp. 249–58, doi:<a href=\"https://doi.org/10.21741/9781644902479-27\">10.21741/9781644902479-27</a>.","short":"J. Lückenkötter, J.P. Leimbach, T. Stallmeister, T. Marten, T. Tröster, in: Materials Research Proceedings, Materials Research Forum LLC, 2023, pp. 249–258.","apa":"Lückenkötter, J., Leimbach, J. P., Stallmeister, T., Marten, T., &#38; Tröster, T. (2023). Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector. <i>Materials Research Proceedings</i>, <i>28</i>, 249–258. <a href=\"https://doi.org/10.21741/9781644902479-27\">https://doi.org/10.21741/9781644902479-27</a>","ama":"Lückenkötter J, Leimbach JP, Stallmeister T, Marten T, Tröster T. Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector. In: <i>Materials Research Proceedings</i>. Vol 28. Materials Research Forum LLC; 2023:249-258. doi:<a href=\"https://doi.org/10.21741/9781644902479-27\">10.21741/9781644902479-27</a>","chicago":"Lückenkötter, Julian, J.P. Leimbach, Tim Stallmeister, Thorsten Marten, and Thomas Tröster. “Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector.” In <i>Materials Research Proceedings</i>, 28:249–58. Materials Research Forum LLC, 2023. <a href=\"https://doi.org/10.21741/9781644902479-27\">https://doi.org/10.21741/9781644902479-27</a>.","ieee":"J. Lückenkötter, J. P. Leimbach, T. Stallmeister, T. Marten, and T. Tröster, “Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector,” in <i>Materials Research Proceedings</i>, Krakow, Poland, 2023, vol. 28, pp. 249–258, doi: <a href=\"https://doi.org/10.21741/9781644902479-27\">10.21741/9781644902479-27</a>."},"intvolume":"        28","page":"249-258","publication_status":"published","publication_identifier":{"eissn":["978-1-64490-247-9"]},"conference":{"location":"Krakow, Poland","end_date":"2023-04-21","start_date":"2023-04-19","name":"ESAFORM 2023"},"doi":"10.21741/9781644902479-27","date_updated":"2023-05-01T09:18:12Z","author":[{"first_name":"Julian","id":"45543","full_name":"Lückenkötter, Julian","last_name":"Lückenkötter"},{"last_name":"Leimbach","full_name":"Leimbach, J.P.","first_name":"J.P."},{"last_name":"Stallmeister","id":"45538","full_name":"Stallmeister, Tim","first_name":"Tim"},{"first_name":"Thorsten","last_name":"Marten","id":"338","full_name":"Marten, Thorsten"},{"first_name":"Thomas","full_name":"Tröster, Thomas","id":"553","last_name":"Tröster"}],"volume":28,"status":"public","type":"conference","_id":"44154","user_id":"45543","department":[{"_id":"9"},{"_id":"321"},{"_id":"149"}],"year":"2023","quality_controlled":"1","title":"Feasibility Study of Compression Molding for Large Reinforcement Structures in the Commercial Vehicle Sector","publisher":"Materials Research Forum LLC","date_created":"2023-04-24T14:14:11Z","abstract":[{"lang":"eng","text":"<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>"}],"publication":"Materials Research Proceedings","keyword":["Compression Molding","Fiber Content","Process Development","Lightweight Design"],"language":[{"iso":"eng"}]}]