Simulation Framework for Cost-Effective One-Shot Forming of Steel-Based Fibre Metal Laminates in Lightweight Automotive Structures

Abstract Recently, there was an increase in the demand for lightweight, high-performance automotive structures, which has induced an interest in steel-based fibre metal laminates (FMLs). The conventional separate heating and forming stages for the metal and fibre-reinforced polymer (FRP) are time- and cost-consuming, which limits the industrial applications. This study presents a simulation-driven methodology for cost-effective one-shot forming of steel (DP780) and FRP (GF/PA6). A coupled thermo-mechanical model is created in Abaqus to represent the nonlinear response of FRP stacks, accounting for temperature-dependent material properties and interactions between FRP layers and steel. The simulation predicts key process defects, including steel–FRP interfacial gaps, FRP delamination, and excessive thickness deviations. The results show good agreement with experimental trials, confirming the model’s accuracy. The simulation framework demonstrates its capability to model the novel forming process for FMLs and to implement it in the industrial-scale production of lightweight, high-performance automotive FML components.