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Process Development for Hybrid Brake Pedals Using Compression Molding with Integrated In-Mold Assembly
Deviprasad Chalicheemalapalli Jayasankar1, Tim Stallmeister1, Julian Lückenkötter1
1Institute for Lightweight Design with Hybrid Systems (ILH), Automotive Lightweight Design (LiA), Paderborn University, Warburger Str. 100, 33098 Paderborn, Germany.
Polymers
|June 27, 2025
Summary
This study introduces a novel one-step In-Mold Assembly (IMA) process for creating lightweight automotive hybrid components. This method significantly reduces production time and cost while achieving a 35% weight reduction in a hybrid brake pedal.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Automotive Engineering
Background:
- Growing demand for resource efficiency and CO2 reduction in automotive production.
- Focus on lightweight components to reduce vehicle weight without compromising safety.
- Hybrid designs offer a solution for weight reduction and improved mechanical performance.
Purpose of the Study:
- To develop and validate a one-step manufacturing process for hybrid automotive components.
- To integrate forming and bonding of fiber-reinforced plastic (FRP) and metal components.
- To reduce production time and costs compared to conventional methods.
Main Methods:
- Development of a novel In-Mold Assembly (IMA) process using compression molding.
- Simultaneous forming and bonding of glass-mat-reinforced thermoplastic (GMT) between metal belts.
- Validation through the production of a lightweight hybrid brake pedal.
Main Results:
- Achieved a 35% weight reduction in the hybrid brake pedal compared to a steel reference.
- Maintained mechanical performance under quasi-static loading.
- Demonstrated a significant reduction in production time and cost.
Conclusions:
- The one-step IMA process is a viable and efficient method for producing lightweight hybrid automotive components.
- This approach supports sustainable automotive production through resource efficiency and weight reduction.
- The developed process offers optimized material distribution for enhanced load-bearing and functional performance.
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