HybCar | Resource-efficient lightweight construction for the automotive industry

Technologies for the efficient production of hybrid CFRP/metal structural components in the automotive sector

The automotive industry in particular is currently placing high expectations on lightweight construction in order to meet environmental requirements. Carbon fiber reinforced plastics with their high specific mechanical characteristics in combination with the good impact properties of steel can meet these expectations. The joint project MAI CC4.0 "HybCar" (FKZ: NW-1705-0013) embedded in the Campus Carbon 4.0 addresses in particular the resource-efficient lightweight construction for the automotive sector, which is to be made possible by the use of metallic substrates and a load-path-compatible use of carbon fibers, taking into account the Industry 4.0 idea. In cooperation with our project partners we are significantly involved in the calculation and efficient production of hybrid CFRP/metal structural components.

Lightweight construction, resource efficiency, cost optimization

Carbon fiber reinforced tapes based on thermoplastic matrix are to be deposited on metallic substrates in accordance with the load path and thus lightweight components are to be manufactured with consideration of resource-saving material use. In doing so, an integrated digital product development should contribute to optimize the flow of materials, the manufacturing process and the costs.


Hybrid mixed construction methods

The lightweight construction potential of hybrid mixed construction methods will be demonstrated using the example of a body structure from the automotive sector. This component will be implemented and validated in hybrid construction in the form of a prototype within the framework of the project, whereby the production of the prototype is preceded by digital product development. This includes the further development of automated semi-finished product deposition of thermoplastic tapes on metallic substrates using the fiber placement process, the development and simulation of the forming process for hybrid structures and the development of suitable process monitoring systems. In addition, an individually adapted tape with surface functionalization for ideal adhesion of tape and metal is generated and characterized in the course of detailed material investigations.

Deep drawing of a CFRP/metal hybrid structure (experimental)
© Fraunhofer IGCV
Deep drawing of a CFRP/metal hybrid structure (experimental)
Deep drawing of a CFRP/metal hybrid structure (simulative)
© Fraunhofer IGCV
Deep drawing of a CFRP/metal hybrid structure (simulative)

Experimental forming investigations and numerical process simulation

The Fraunhofer IGCV focuses on the development of the forming process of the hybrid structure within the framework of the joint project. This includes experimental forming investigations as well as numerical process simulation. Here the Fraunhofer IGCV can draw on know-how from previous projects, such as the aerospace research project GeKo-Therm (FKZ: 20H1311B) or the project MAI re-car (FKZ:03MAI34E) and is therefore predestined to carry out the work package.

Furthermore, the Fraunhofer IGCV takes over the material modeling for the structure simulation with Abaqus. Especially the numerical representation of the boundary layer between thermoplastic tape and metal substrate is part of the work. This is essential for a simulative design of the demonstrator with regard to the necessary stiffness and crash behavior.


Cooperation with Fraunhofer IGCV

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Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles


We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.