Experimental investigation of a new hybrid molding process to manufacture high-performance composites

Reducing vehicle weight to reduce energy consumption and engine emissions is one of the major objectives of the automotive industry. The novel molding technology, presented in this paper, is suited to meet this demand. In this process, a thermoformed fiber-reinforced thermoplastic sheet is inserted into the mold and a long-fiber reinforced thermoplastic is injected to form a rib structure. Short cycle times make the technique an economic option for the manufacturing of hybrid high performance composites. This special integrative injection molding method optimizes efficiencies and thus energy consumption. A basic concept was realized to show the manufacture procedure. The mechanism of adhesion bonding between the long fiber thermoplastic material and the formed fabric and the influence of the main injection molding process parameters on the adhesion quality was experimentally investigated according to the Design of Experiments method. Then experimental tests were used to measure the structural properties of hybrid composites.