Hybrid technology, also known as plastic/metal composite technology, combines the specific strengths of plastic with those of metals such as sheet steel and aluminum. It allows geometries such as large flat surfaces that would not be possible with only one material through the use of metal sheet plus complex ribbing using injection molding material.

When manufacturing a hybrid component, plastic ribbing and reinforcements are molded onto metal parts and profiles. Compared with conventional injection molding, the hybrid technology makes it possible to produce complex structures that were previously inconceivable with thermoplastics. The positive connection created in the injection molding process between the plastic and the metal inserts of the hybrid component facilitates the production of components that have a high load-bearing capacity but are nevertheless inexpensive. The injection molding process delivers consistently high, reproducible quality.

These plastic moldings improve the mechanical strength of the metal structure by improving the application and distribution of forces in the component. Basically, it is possible either to gain weight advantages without compromising on performance, or to improve performance without increasing weight.

LANXESS, as a pioneer of hybrid technology, has extensive technological know-how, which already flows into the initial development of a new component in partnership with the manufacturer. This know-how extends from the materials used and the design and calculation of the parts to the production processes and testing methods.

Front ends – a classic example of hybrid technology

Hybrid technology has become established above all in car manufacture. The most prominent example is the production of lightweight, highly integrated front ends with outstanding load resistance. The product portfolios of almost all the big-name automakers feature models equipped with hybrid front ends based on these thermoplastics. Over 50 million hybrid front ends for more than 70 vehicle models have now been manufactured in series production using sheet steel and various grades of Durethan® polyamide 6 (PA 6) from LANXESS.

Diverse applications

In recent years, LANXESS has extended the range of application for this type of lightweight construction. For example, roof frames and roof rack modules for panorama roofs, doors, hoods and flaps, instrument panel supports, seat cross-members, door sills and B pillars are now manufactured by the hybrid system. Another example is that of brake pedals and pedal brackets for vehicles from various manufacturers, which are produced from Durethan® BKV 30 H2.0. A pedal of this kind is stabilized with a rib structure of plastic. Compared to a version made only of steel, this pedal delivers more load-bearing capacity and weighs around 40 percent less. A number of other constructional details such as bearing and switch mountings are integrated. An additional safety-related benefit is that, in the event of a crash, the hybrid part does not break but becomes deformed.