{"issue":"12","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>","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).","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>.","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>","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>."},"publication":"Polymers","department":[{"_id":"9"},{"_id":"321"},{"_id":"149"}],"publication_identifier":{"issn":["2073-4360"]},"publication_status":"published","oa":"1","intvolume":"        17","_id":"60210","language":[{"iso":"eng"}],"title":"Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly","publisher":"MDPI AG","volume":17,"type":"journal_article","date_updated":"2025-06-15T20:23:49Z","author":[{"orcid":"https://orcid.org/ 0000-0002-3446-2444","full_name":"Chalicheemalapalli Jayasankar, Deviprasad","last_name":"Chalicheemalapalli Jayasankar","first_name":"Deviprasad","id":"49504"},{"last_name":"Stallmeister","full_name":"Stallmeister, Tim","first_name":"Tim","id":"45538"},{"id":"45543","first_name":"Julian Janick Stefan","last_name":"Lückenkötter","full_name":"Lückenkötter, Julian Janick Stefan"},{"last_name":"Tröster","full_name":"Tröster, Thomas","id":"553","first_name":"Thomas"},{"first_name":"Thorsten","id":"338","orcid":"0009-0001-6433-7839","full_name":"Marten, Thorsten","last_name":"Marten"}],"article_number":"1644","user_id":"49504","year":"2025","main_file_link":[{"url":"https://www.mdpi.com/2073-4360/17/12/1644","open_access":"1"}],"date_created":"2025-06-15T20:16:14Z","status":"public","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>"}],"doi":"10.3390/polym17121644"}