Fast and efficient automotive hybrid part manufacturing process using polyurethane-based prepregs

A polyurethane-based prepreg with high metal adhesion is developed which enables a fast and efficient process route towards metal FRP hybrid parts. Forming of metal and FRP is achieved in a single step due to thermoplastic processing of the thermoset matrix. Cycle times can be reduced to below one minute for body-in-white parts since the time-consuming post curing step can be integrated into the cathodic dip coating process. The final demonstrator parts exhibit high bonding strengths between metal and FRP without the need for adhesives or metal pre-treatment.