---
_id: '60210'
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>
article_number: '1644'
author:
- first_name: Deviprasad
  full_name: Chalicheemalapalli Jayasankar, Deviprasad
  id: '49504'
  last_name: Chalicheemalapalli Jayasankar
  orcid: https://orcid.org/ 0000-0002-3446-2444
- first_name: Tim
  full_name: Stallmeister, Tim
  id: '45538'
  last_name: Stallmeister
- first_name: Julian Janick Stefan
  full_name: Lückenkötter, Julian Janick Stefan
  id: '45543'
  last_name: Lückenkötter
- first_name: Thomas
  full_name: Tröster, Thomas
  id: '553'
  last_name: Tröster
- first_name: Thorsten
  full_name: Marten, Thorsten
  id: '338'
  last_name: Marten
  orcid: 0009-0001-6433-7839
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>
  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>
  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} }'
  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>.'
  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).
date_created: 2025-06-15T20:16:14Z
date_updated: 2026-03-20T08:44:36Z
department:
- _id: '9'
- _id: '321'
- _id: '149'
doi: 10.3390/polym17121644
intvolume: '        17'
issue: '12'
language:
- iso: eng
main_file_link:
- open_access: '1'
  url: https://www.mdpi.com/2073-4360/17/12/1644
oa: '1'
publication: Polymers
publication_identifier:
  issn:
  - 2073-4360
publication_status: published
publisher: MDPI AG
quality_controlled: '1'
status: public
title: Process Development for Hybrid Brake Pedals Using Compression Molding with
  Integrated In-Mold Assembly
type: journal_article
user_id: '49504'
volume: 17
year: '2025'
...
---
_id: '48586'
author:
- first_name: Julian
  full_name: Lückenkötter, Julian
  id: '45543'
  last_name: Lückenkötter
- first_name: Simon
  full_name: Aydin, Simon
  last_name: Aydin
- first_name: Thorsten
  full_name: Marten, Thorsten
  id: '338'
  last_name: Marten
- first_name: Thomas
  full_name: Tröster, Thomas
  id: '553'
  last_name: Tröster
citation:
  ama: 'Lückenkötter J, Aydin S, Marten T, Tröster T. Analysis and Optimization of
    Joint Formation in Hybrid Compression Molding. 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.
  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}
    }'
  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.
  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.'
conference:
  end_date: 2023-08-04
  location: Belfast
  name: 23nd International Conference on Composite Materials (ICCM23 2023)
  start_date: 2023-07-31
date_created: 2023-11-02T08:29:45Z
date_updated: 2023-11-02T08:30:43Z
department:
- _id: '321'
- _id: '9'
- _id: '149'
language:
- iso: eng
status: public
title: Analysis and Optimization of Joint Formation in Hybrid Compression Molding
type: conference
user_id: '45543'
year: '2023'
...
---
_id: '45831'
author:
- first_name: Deviprasad
  full_name: Chalicheemalapalli Jayasankar, Deviprasad
  id: '49504'
  last_name: Chalicheemalapalli Jayasankar
  orcid: https://orcid.org/ 0000-0002-3446-2444
- first_name: Tim
  full_name: Stallmeister, Tim
  id: '45538'
  last_name: Stallmeister
- first_name: Julian
  full_name: Lückenkötter, Julian
  id: '45543'
  last_name: Lückenkötter
- first_name: Thomas
  full_name: Tröster, Thomas
  id: '553'
  last_name: Tröster
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.'
  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 .
  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} }'
  chicago: Chalicheemalapalli Jayasankar, Deviprasad, Tim Stallmeister, Julian Lückenkötter,
    and Thomas Tröster. “In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression
    Molding,” 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.
  mla: Chalicheemalapalli Jayasankar, Deviprasad, et al. <i>In-Mold Assembly of Hybrid
    GMT-Steel Brake Pedals by Compression Molding</i>. 2023.
  short: 'D. Chalicheemalapalli Jayasankar, T. Stallmeister, J. Lückenkötter, T. Tröster,
    in: 2023.'
conference:
  end_date: 2023-06-23
  location: 'Trondheim, Norway '
  name: 5th International Conference on Light Materials - Science and Technology LightMAT
    2023
  start_date: 2023-06-21
date_created: 2023-07-03T08:23:15Z
date_updated: 2024-03-26T09:19:44Z
ddc:
- '620'
department:
- _id: '9'
- _id: '321'
- _id: '149'
file:
- access_level: closed
  content_type: application/pdf
  creator: dcj
  date_created: 2023-07-03T08:15:04Z
  date_updated: 2023-07-03T08:15:04Z
  file_id: '45832'
  file_name: LightMAT-2023_Extended Abstract.pdf
  file_size: 359467
  relation: main_file
  success: 1
file_date_updated: 2023-07-03T08:15:04Z
has_accepted_license: '1'
keyword:
- Compression Molding
- Glass Mat Thermoplastics
- Hybrid Brake Pedal
language:
- iso: eng
status: public
title: In-Mold Assembly of Hybrid GMT-Steel Brake Pedals by Compression Molding
type: conference_abstract
user_id: '49504'
year: '2023'
...
---
_id: '44154'
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>
author:
- first_name: Julian
  full_name: Lückenkötter, Julian
  id: '45543'
  last_name: Lückenkötter
- first_name: J.P.
  full_name: Leimbach, J.P.
  last_name: Leimbach
- first_name: Tim
  full_name: Stallmeister, Tim
  id: '45538'
  last_name: Stallmeister
- first_name: Thorsten
  full_name: Marten, Thorsten
  id: '338'
  last_name: Marten
- first_name: Thomas
  full_name: Tröster, Thomas
  id: '553'
  last_name: Tröster
citation:
  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>'
  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>
  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} }'
  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>.'
  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.'
conference:
  end_date: 2023-04-21
  location: Krakow, Poland
  name: ESAFORM 2023
  start_date: 2023-04-19
date_created: 2023-04-24T14:14:11Z
date_updated: 2023-05-01T09:18:12Z
department:
- _id: '9'
- _id: '321'
- _id: '149'
doi: 10.21741/9781644902479-27
intvolume: '        28'
keyword:
- Compression Molding
- Fiber Content
- Process Development
- Lightweight Design
language:
- iso: eng
page: 249-258
publication: Materials Research Proceedings
publication_identifier:
  eissn:
  - 978-1-64490-247-9
publication_status: published
publisher: Materials Research Forum LLC
quality_controlled: '1'
status: public
title: Feasibility Study of Compression Molding for Large Reinforcement Structures
  in the Commercial Vehicle Sector
type: conference
user_id: '45543'
volume: 28
year: '2023'
...