{"id":12093,"date":"2026-03-30T15:22:39","date_gmt":"2026-03-30T13:22:39","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/"},"modified":"2026-04-07T14:51:27","modified_gmt":"2026-04-07T12:51:27","slug":"bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/","title":{"rendered":"Composite properties in back-moulding metallic three-dimensional Surfi-Sculpt form-locking elements"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_bb9d2e5ebf213bf42ba11bd796272d33 .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_bb9d2e5ebf213bf42ba11bd796272d33 .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_bb9d2e5ebf213bf42ba11bd796272d33\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                                    <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Plastic\/metal hybrid components combine the advantages of both materials, while optimising the weight-performance-ratio. In the HySurf project, the IKV is working in cooperation with the Institute for Welding and Joining Technology at RWTH Aachen University (ISF) to develop a methodology for predicting the failure behaviour of back-injected hybrid components with Surfi-Sculpt structures based on process and material parameters.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund-748x386.png 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund-1536x793.png 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund-768x396.png 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"793\" alt=\"Prozessablauf-zur Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschl\u00fcssigen-Surfi-Sculpt-Verbund\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: Production process for manufacturing plastic\/metal hybrid components using form-fitting Surfi-Sculpt closure<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">When manufacturing plastic\/metal hybrid components, the foreign materials can be connected by welding, glueing or integrated back-moulding, which often necessitates a form fit or primer. Form-fitting mechanisms, such as back-moulding <em>Surfi-Sculpt<\/em> structures, offer several advantages: They can be used independently of the material and allow the separation of the component in the context of <em>Design for Disassembly<\/em>. They also enable a more complex connection between metal and plastic through a combination of elevation and indentation. However, the precise design and positioning of these structures regarding melt pressures during back-moulding, different load directions during usage and separability at the end of life present a central challenge.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><br>In cooperation with the Institute for Welding and Joining Technology at RWTH Aachen University (ISF), a methodology is developed to predict the failure behaviour of back-moulded hybrid components with <em>Surfi-Sculpt<\/em> structures, considering the material characteristics and processing conditions during structuring as well as back-moulding. To this end, various structural geometries in different orientations are created in and on the metal part before it is back-moulded in an integrated process. The produced plastic\/metal hybrid components are mechanically and microscopically analysed to determine the influence of the structure on the bonding strength, weld line formation and breakage behaviour, using both experimental and simulation-based methods.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the DFG for funding the project (funding reference HO 4776\/101-1) and the project partners for<br>the cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.07.2025 \u2013 31.12.2025<\/p>\n\n\n<section id=\"logo-bar-block_b2dd4e012c91aaf4d64e60145aa97238\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG-748x591.png 748w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"748\" height=\"591\" alt=\"Logo-DFG\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>Plastic\/metal hybrid components combine the specific advantages of both materials to reduce weight and increase mechanical performance. In the HySurf project, IKV, in cooperation with the Institute of Welding and Joining Technology at RWTH Aachen University (ISF), is developing a methodology for predicting the failure behavior of back-injected hybrid components with Surfi-Sculpt structures on the basis of process and material parameters.<\/p>\n","protected":false},"featured_media":12089,"parent":0,"template":"","tags":[1033,928,921,952],"research_fields":[813,1027],"class_list":["post-12093","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-back-injection-back-molding","tag-hybrid-parts","tag-injection-moulding","tag-joining-technology","research_fields-injection-moulding","research_fields-joining-technologies"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Composite properties in back-moulding metallic three-dimensional Surfi-Sculpt form-locking elements | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Plastic\/metal hybrid components combine the specific advantages of both materials to reduce weight and increase mechanical performance. In the HySurf project, IKV, in cooperation with the Institute of Welding and Joining Technology at RWTH Aachen University (ISF), is developing a methodology for predicting the failure behavior of back-injected hybrid components with Surfi-Sculpt structures on the basis of process and material parameters.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Composite properties in back-moulding metallic three-dimensional Surfi-Sculpt form-locking elements | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"Plastic\/metal hybrid components combine the specific advantages of both materials to reduce weight and increase mechanical performance. In the HySurf project, IKV, in cooperation with the Institute of Welding and Joining Technology at RWTH Aachen University (ISF), is developing a methodology for predicting the failure behavior of back-injected hybrid components with Surfi-Sculpt structures on the basis of process and material parameters.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/\" \/>\n<meta property=\"og:site_name\" content=\"IKV-Aachen\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/profile.php?id=523026911193540&amp;_rdr\" \/>\n<meta property=\"article:modified_time\" content=\"2026-04-07T12:51:27+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund.png\" \/>\n\t<meta property=\"og:image:width\" content=\"2274\" \/>\n\t<meta property=\"og:image:height\" content=\"1174\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/png\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\\\/\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\\\/\",\"name\":\"Composite properties in back-moulding metallic three-dimensional Surfi-Sculpt form-locking elements | IKV-Aachen\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2025\\\/03\\\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund.png\",\"datePublished\":\"2026-03-30T13:22:39+00:00\",\"dateModified\":\"2026-04-07T12:51:27+00:00\",\"description\":\"Plastic\\\/metal hybrid components combine the specific advantages of both materials to reduce weight and increase mechanical performance. 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In the HySurf project, IKV, in cooperation with the Institute of Welding and Joining Technology at RWTH Aachen University (ISF), is developing a methodology for predicting the failure behavior of back-injected hybrid components with Surfi-Sculpt structures on the basis of process and material parameters.","breadcrumb":{"@id":"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/#breadcrumb"},"inLanguage":"en-GB","potentialAction":[{"@type":"ReadAction","target":["https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/"]}]},{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/#primaryimage","url":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund.png","contentUrl":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/03\/Prozessablauf-zur-Herstellung-von-Kunststoff-Metall-Hybridbauteilen-durch-formschluessigen-Surfi-Sculpt-Verbund.png","width":2274,"height":1174,"caption":"Fig. 1: Production process for manufacturing plastic\/metal hybrid components using form-fitting Surfi-Sculpt closure"},{"@type":"BreadcrumbList","@id":"https:\/\/ikv-aachen.de\/en\/rp\/bonding-properties-when-back-molding-metallic-three-dimensional-surfi-sculpt-form-fit-elements\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/ikv-aachen.de\/en\/"},{"@type":"ListItem","position":2,"name":"Composite properties in back-moulding metallic three-dimensional Surfi-Sculpt form-locking elements"}]},{"@type":"WebSite","@id":"https:\/\/ikv-aachen.de\/en\/#website","url":"https:\/\/ikv-aachen.de\/en\/","name":"IKV-Aachen","description":"Forschung f\u00fcr die Praxis","publisher":{"@id":"https:\/\/ikv-aachen.de\/en\/#organization"},"alternateName":"Institut f\u00fcr Kunststoffverarbeitung","potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/ikv-aachen.de\/en\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-GB"},{"@type":"Organization","@id":"https:\/\/ikv-aachen.de\/en\/#organization","name":"IKV-Aachen","alternateName":"Institut f\u00fcr Kunststoffverarbeitung (IKV)","url":"https:\/\/ikv-aachen.de\/en\/","logo":{"@type":"ImageObject","inLanguage":"en-GB","@id":"https:\/\/ikv-aachen.de\/en\/#\/schema\/logo\/image\/","url":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/02\/ikv-ikv-1.png","contentUrl":"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2025\/02\/ikv-ikv-1.png","width":512,"height":512,"caption":"IKV-Aachen"},"image":{"@id":"https:\/\/ikv-aachen.de\/en\/#\/schema\/logo\/image\/"},"sameAs":["https:\/\/www.facebook.com\/profile.php?id=523026911193540&_rdr","https:\/\/www.instagram.com\/ikvaachen\/"]}]}},"_links":{"self":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/rp\/12093","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/rp"}],"about":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/types\/cpt_ikv_rp"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/media\/12089"}],"wp:attachment":[{"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/media?parent=12093"}],"wp:term":[{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/tags?post=12093"},{"taxonomy":"research_fields","embeddable":true,"href":"https:\/\/ikv-aachen.de\/en\/wp-json\/wp\/v2\/research_fields?post=12093"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}