Hybridisation is a major topic in mechanical engineering due to the limitations of individual technologies. Drawbacks are substituted and benefits enhanced by the combination of different technologies. Furthermore, hybridisation serves as a bridging technology till a single technology is fully developed. Hence, various types of hybridisation can be found in literature, like processes, machines, materials and structures.

The integration of an additively manufactured (AM) metallic insert by tailored fibre placement (TFP) and shaping the whole structure by resin transfer moulding (RTM) is a hybrid component in terms of the material as well as manufacturing process. To face the challenges of different material characteristics, like stiffness, and the bonding in between the two material classes the opportunities within additive manufacturing are analysed. At the same time the requirements of TFP and RTM processes need to be considered. Both is done by the help of methodical, simulative and experimental approaches. In a first step different AM “thin”-metal parts were bonded with woven carbon fibre by vacuum assisted RTM (VARTM) and tested for tensile-shear performance. The results are going to be used to model the bonding behaviour in the simulations for complex shaped metallic inserts more accurately.

Especially within the field of additive manufacturing, hybridisation is a common way to benefit from its potentials and to enhance the field of application. Due to the novelty and variability of this technology, design engineers need to be supported even more. This can be done by sufficiently provided design guidelines (DG). The results of the simulations and experiments mentioned above will serve to develop such guidelines.