Design Technology: Developing Plastics and Metal Hybrid Parts

Increasing thrust on lower weight, cost-efficient designs and optimized life cycles are driving metal replacement. Plastics also enable integration of increasing number of functions in an individual application by reducing part count, easy finishing and assembly steps. However many metal applications are not easily replaced as metals excel in many aspects over plastics, notable in higher modulas, higher temperatures of use, conductivity and better dimensional stability. Therefore substitution is possible only in limited areas or through creative design and engineering, by developing hybrid parts, that leverage the best of both, metals and non-metals to deliver functionality and performance levels that cannot be achieved either by plastics or by metal parts.

Applications providing high-modulus and strength, combined with light weight and aesthetics are being increasingly developed. And challenges remain in such hybrid approaches in easy recyclability and lifecycle management when using certain techniques such as insert molding or molded interconnect devices, etc. This is where expertise to develop solutions in hybrid plastics and metal parts comes in – and is the focus of this module.

It is common knowledge that most plastics insulating and most metals are conducting. Plastics also have a much greater coefficient of thermal expansion than metals; and structural performance, effects and limits widely vary between metals and plastics. The methods of production, secondary operations, finishing and assembly are quite dissimilar as well.

Any hybrid solution has to account for all these factors while optimally bringing the desired value of combined solution. If implemented well plastics and metal hybrids can achieve very sophisticated feaures and benefits ranging from performance and costs to environmental and energy impact.

This module focusses on techniques of designing for plastic and metal hybrids and how to avoid costly mistakes. With real life case studies and examples you can learn not just the methods but build start building your solutions quickly.

© Copyright 2018. First Published by Pradeep Chowdhary

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The full course is also available at udemy.com starting Sept, 2018.

Approx. Duration: 2 hrs.

Level: Intermediate to Advanced