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Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly.

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Title: Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly.
Authors: Chalicheemalapalli Jayasankar, Deviprasad1 (AUTHOR) deviprasad.jayasankar@uni-paderborn.de, Stallmeister, Tim1 (AUTHOR), Lückenkötter, Julian1 (AUTHOR), Tröster, Thomas1 (AUTHOR), Marten, Thorsten1 (AUTHOR)
Source: Polymers (20734360). Jun2025, Vol. 17 Issue 12, p1644. 18p.
Subjects: Compression molding, Sustainability, Fiber-reinforced plastics, Functional integration, Automobile industry
Abstract: 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 [ABSTRACT FROM AUTHOR]
Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
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PubTypeId: academicJournal
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  Data: Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly.
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  Data: <searchLink fieldCode="JN" term="%22Polymers+%2820734360%29%22">Polymers (20734360)</searchLink>. Jun2025, Vol. 17 Issue 12, p1644. 18p.
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  Data: <searchLink fieldCode="DE" term="%22Compression+molding%22">Compression molding</searchLink><br /><searchLink fieldCode="DE" term="%22Sustainability%22">Sustainability</searchLink><br /><searchLink fieldCode="DE" term="%22Fiber-reinforced+plastics%22">Fiber-reinforced plastics</searchLink><br /><searchLink fieldCode="DE" term="%22Functional+integration%22">Functional integration</searchLink><br /><searchLink fieldCode="DE" term="%22Automobile+industry%22">Automobile industry</searchLink>
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  Data: 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 [ABSTRACT FROM AUTHOR]
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  Label:
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  Data: <i>Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/polym17121644
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      – Code: eng
        Text: English
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      – SubjectFull: Fiber-reinforced plastics
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            NameFull: Chalicheemalapalli Jayasankar, Deviprasad
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              M: 06
              Text: Jun2025
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              Y: 2025
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