PreFiHy - prefinished light metal polymer hybrid parts

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The European collective research project involves a consortium of institutions, including the Fraunhofer Institute of Machine Tools and Forming Technology IWU, the Leibniz Institute of Polymer Research Dresden, the Belgian Centre for Research in Metallurgy, and Sirris. The focus is on developing technologies and processes for efficiently manufacturing hybrid parts. The innovative approach connects metal and plastic through a unique 2-in-1 powder-coating system that serves as both an adhesion promoter and surface finisher. This functional powder coating integrates a latent adhesive function for chemical bonding in subsequent industrial processes, such as injection molding, enabling the creation of high-strength multi-material parts in a cost-effective manner. By introducing this high-performance coating system, product costs can be reduced by up to 25%, minimizing the need for pre-treatment steps and additional adhesive applications. The Leibniz Institute produced several powder coating systems utilizing a new crosslinking mechanism, aiming for maximum bonding strength while maintaining forming stability. Concurrently, the Belgian Centre developed an efficient roll coating method for pre-treating aluminum sheets. To assess the forming stability of various coatings, the Fraunhofer IWU created a testing concept that allowed for the selection of optimal systems. Demonstrations using automotive components showcased the advantages