Self-supporting 3-D printed chassis structures are disclosed. Self-supporting ribs are selectively printed to walls of the structure to meet desired dynamic stiffness targets while maintaining a reduced mass. The self-supporting ribs can be used as both support structures (e.g., for outer walls) during 3-D printing and as stiffening structures when the chassis structure is in operation. In an embodiment, the chassis structure is printed such that no support structures are needed. Topology optimization can enable remaining unneeded internal ribs or supports to be removed, and a high inner spatial volume between ribs can be maintained to make maximum use of the part. In various embodiments, wall thicknesses can be maintained at or below 1-2 millimeters, which further reduces mass.

The present disclosure relates to a system for manufacturing a hybrid component including a first thermal supplier configured to heat a steel plate, a rolling roll for undercut configured to pressurize the steel plate heated by the first thermal supplier, and to form an undercut on one surface of the steel plate, a first molding roll configured to pressurize the steel plate formed with the undercut to mold the steel plate in a shape of a component to be manufactured, a composite material feeder configured to supply a composite material tape to be seated on one surface of the steel plate formed with the undercut through the first molding roll, and a composite material pressurization roll configured to pressurize the steel plate on which the composite material tape is seated.

Methods of producing polymer-metal hybrid components that are bonded by CO-M bonds at the interface using at least one of the hot pressing, rolling, and injection molding methods to create chemical bond formation conditions at the polymer and metal interface. When the thermal cycle and compressive pressure specified herein is combinationally created at the polymer and metal interfaced, strong CO-M bonds forms at the interface and strongly bonds the metal and polymer together through the reaction carbonyl groups (CO) in polymer and the metal surface. For polymers lacking enough carbonyl groups, new functional groups can be in-situ generation through introducing distributed air pockets at the polymer-metal interface for forming 3-dimensional distributed CO-M bonds at the interface.

In a method for connecting an attachment part to a structural part of a bodywork, a wall of the structural part is formed to at least partly encircle a region of the structural part. A form element is arranged to a main body of the attachment part. The attachment part is placed in the region of the structural part such that the form element touches the wall of the structural part, and the attachment part is pushed into the region, thereby causing the form element to move in relation to the main body of the attachment part until reaching an aperture in the wall of the structural part so that the form element moves into the aperture and is arranged therein to thereby position the attachment part in the region of the structural part.

A process for producing a plate-like body with a resin frame having a decorative molding, wherein the decorative molding includes a main part and a film formed on a surface and has a design part exposed on a surface of the resin frame and an embedded part in the resin frame. The film continuously covers the design part and the embedded part. The process includes a step of mounting the decorative molding on a mold for forming the resin frame and further mounting a plate-like body, and a step of injecting a molten resin into a cavity of the mold and forming a resin frame with the decorative molding thereon into a window glass while a film at a portion located at a boundary between the design part and the embedded part is pressed against the mold by an injection pressure of the molten resin and thermally deformed.

An assembly is provided that includes a castellated upper substrate defining a plurality of alternating troughs and ridges. A lower substrate is disposed adjacent the upper castellated substrate, and an adhesive material is disposed between the castellated upper substrate and the lower substrate. A fastener extends through a trough of the castellated upper substrate, through the adhesive material, and into the lower substrate. A method of assembling the upper and lower substrates is also provided, which includes plastically deforming the castellated upper substrate to reduce an intake of air between the substrates.

An amorphous structure layer is formed on a surface layer of a bonded portion of each of side brackets. A bottomed hole layer including a plurality of bottomed holes is formed on a surface layer of the amorphous structure layer. Each of the bottomed holes has a reverse-tapered shape, which has, between an opening portion and a bottom portion of each of the bottomed holes, a bulged portion having a larger inner circumference than the opening portion. An adhesive is injected into the bottomed holes. An outer circumferential surface of the bonded portion of each of the side brackets and an inner circumferential surface of an end portion of a center beam face toward each other with the adhesive interposed therebetween.

A hybrid structure, comprising: a frame member comprising at least three walls forming a channel having a convex portion where two walls meet; a concave deformation in at least one of the convex portions, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion; and a plastic reinforcement member in the channel, wherein a portion of the reinforcement member extends into the opening and on the deformation.

The invention concerns a method for producing a hybrid-structure part of a motor vehicle, comprising shaping of a sheet of metallic material, the provision of a sheet of composite material, application of a layer of connecting material on a face of said metallic material sheet or on a face of said composite material sheet, the shaping of a hybrid element by shaping said composite material sheet to the shape of said metallic material sheet and joining the composite material sheet to the metallic material sheet by means of said connecting material layer, and the production of rigidification elements by overmoulding using a polymer material.

An assembly comprising a substrate 1, a substrate 2 and heat curable adhesive, which is positioned between the substrates 1 and 2, wherein the heat curable adhesive is cured only in a portion of less than 50% of the entire surface covered by the heat curable adhesive. In this manner, the cured parts of the adhesive serve as chemical screws which sufficiently fix the substrates together during further processing steps, but do not involve complete curing of the adhesive.