This study examines the in-situ production of polymer-metal sandwich hybrids by overmolding laser-structured aluminum inserts with polyamide 6.6 reinforced with 30% glass fibers using injection molding. The PA6.6 GF30-aluminum combination serves as a role model due to its lightweight applications and challenging adhesion properties. Laser structuring of the metal inserts creates micro-scale features, enhancing micromechanical interlocking and thereby improving adhesion and mechanical properties.

In an earlier phase, the optimal laser structuring parameters, such as laser intensity and frequency, were identified to maximize surface roughness and adhesion potential. The current phase focuses on optimizing the injection molding process using a Box-Behnken experimental design, investigating parameters including mold temperature, screw speed and melt temperature. The goal is to achieve strong bonding at the polymer-metal interface, with variothermal mold temperature control applied to facilitate polymer infiltration into the structured surface. Precise temperature control is crucial for managing polymer melt viscosity, which significantly impacts infiltration into the microstructure.

To evaluate the mechanical performance of the hybrid structures, an edge-shear test will be conducted. The expected outcomes include a thorough understanding of the influence of molding parameters on interface strength and overall mechanical integrity. These findings contribute insights into developing an alternative process route for lightweight applications, providing an efficient and reproducible method for high-performance polymer-metal hybrids. The use of variothermal processing in combination with optimized molding conditions is expected to reduce internal stresses and enhance adhesion, making it promising for future manufacturing needs.