Table 4 Summary of alternative hybrid manufacturing approaches for metal-polymer integration
Reference | Method | Joining Mechanism | Materials Used | Potential Application |
|---|---|---|---|---|
Khan et al.102 | FDM on pre-drilled metal | Mechanical interlocking | Polypropylene (PP), Aluminum 5083 | Structural components with embedded reinforcement |
Lambiase et al.101 | Thermocompression joining | Heat and pressure-induced bonding | Various thermoplastics, metal sheets | Multi-material automotive or aerospace structures |
Falck et al.99 | AddJoining (FDM + clamping) | Melted polymer over slotted metal | ABS, PA6-CF, Aluminum 2024-T3 | Lightweight layered hybrid structures |
Ozlati et al.35 | Hybrid platform (FFF + metal DOD) | In-situ metal droplet deposition | PLA, Sn-based solder alloy | 3D printed electronics with conductive paths |
Sun et al.100 | Roll pressing of PTFE on Li metal | Mechanochemical reaction interface | PTFE, Lithium metal | Battery protective layers |
Pokkalla et al.96 | Additive Manufacturing-Compression Overmolding (AM-CM) | Mechanical interlocking via compression of polymer into metal lattice (no adhesive) | Maraging Steel 300 (metal lattice via LPBF) 40% wt. Carbon Fiber Reinforced Polyamide-6,6 (CF/PA66) | Lightweight, high-strength hybrid parts for automotive and structural components |
