In the ZIM cooperation project "HyBend", research is being conducted on "Process development for the one-step production of bending load-optimized hybrid beams made from metal straps and GMT support cores". For this purpose, a hybrid structure based on a mass-produced brake pedal was developed. This structure includes a continuous metal strap designed to optimally absorb the bending loads that occur when initiating the braking process. The metal structure is supported by a load-path-optimized structure made of glass mat-reinforced thermoplastic (GMT). GMT offers high design flexibility and an excellent strength-to-weight ratio.

As part of the process development, simultaneous forming and joining of the different material classes takes place. By combining these processes, manufacturing can be made more cost- and time-efficient, contributing to economically viable lightweight construction. Additional advantages arise from the integration of functional components and the incorporation of supplementary features. For example, an innovative collapsing core can create an undercut perpendicular to the pressing direction, eliminating the need for an additional functional element to accommodate the connecting rod to the brake booster.