Combination of metal forming and injection moulding in one tool

Abstract. In electric vehicles, the mechanical, media and thermal loads are significantly reduced compared to conventional vehicles, whereas at the same time the challenges in terms of electro¬magnetic compatibility, lightweight construction and acoustics are increasing. For this purpose, economically and technically competitive, recyclable electric architecture casings are to be developed. These will be realized as hybrid components in which a thin metal sheet provides the electromagnetic shielding and the polymer component transfers the mechanical loads. For the production, a hybrid process is developed in which deep drawing and injection moulding are combined in one tool. This paper presents the results of component, process and tool development, manufacturing studies, component analysis and recycling tests using a scaled generic test structure.