Context and Overall Objectives

The aim of FlexHyJoin is to develop a pilot scale production cell for joining an application-oriented

multi-material roof stiffener, which is ready for implementation in the automotive industry.


Both materials contribute with their unique properties to create components with enhanced performance. On the one hand, composite parts provide flexibility and good lightweight properties while on the other hand, metals guarantee the necessary structural resistance, resulting in a more favorable performance/cost ratio. Therefore, it is necessary to provide joining technologies for TP-FRPC and metals which guarantee reliable joints in a pilot scale joining process.


Apart from complementing joining technologies the cell is also enhanced by:

  • Fully automated, online process control and supervision
  • Integrated surface pre-treatment
  • Non-Destructive Testing


All in all FlexHyJoin provides an essential enabler technology for future mobility concepts. The final result is an innovative joining process


  • for fiber reinforced polymers and metals,
  • suiting the strict requirements of automotive industry and
  • enabling the broad application of hybrid material systems.


Progress beyond State of the Art and Expected Potential Impact

By the optimum combination of laser and induction joining for components containing both complex and large joining areas, the FlexHyJoin project enables the weight neutral joining of different materials without the use of potentially harmful solvents. The resulting hybrid parts allow for the best use of multi-material systems according to the motto “the right material in the right place” – depending on the applied loads.

Lightweight parts and vehicles will be the consequence, leading to reduced carbon dioxide (CO2) emission during their service life. Additionally, FlexHyJoin will implement a non-destructive online monitoring system, which will allow identifying defects of parts during their manufacturing process without destroying them. This technique contributes to a more sustainable and advanced manufacturing process.