Shin, Geun Sik Cha, Eunho Kang, Dae Young Jung, Jin Young Jeong, Hyeondeok Yu, Siwon Hwang, Jun Yeon 2025-06-24T02:30:21Z 2025-06-24T02:30:21Z 2025-06-23 2025-09 1526-6125 https://pubs.kist.re.kr/handle/201004/152679 Recent studies on metal-plastic bonding have led to growing interest in hybrid 3D printing and joining materials. Until now, most hybrids have focused on printing plastic on metal, excluding metal on plastic. Printing metal on plastic has not been achieved due to significant carbonization of the bottom plastic layer caused by the thermal penetrating of the laser. This research aims to solve this issue by placing a pre-mixture of plastic and metal on the plastic layer. The existing method of laser sintering Ti6Al4V metal on polyethylene terephthalate glycol-modified (PETG) caused mutual permeation between the plastic and metal powders, resulting in a degradation in interfacial adhesion. In contrast, the pre-mixture formed an intermediate interface, preventing the interfacial permeation of powders and suppressing pore formation between the plastic and metal. As a result, the porosity analysis using X-ray tomography shows that the pre-mixture interface effectively suppresses the number of pores between PETG and Ti6Al4V, which is comparatively less than that of the interface without the mixture. This indicates that the pre-mixture strengthens the bond between the plastic and metal while protecting the interface from laser-induced damage. English Elsevier BV Joining of metal-plastic hybrid composites using pre-mixture by laser assisted additive manufacturing process Article 10.1016/j.jmapro.2025.06.006 1 Journal of Manufacturing Processes, v.149, pp.709 - 717 Journal of Manufacturing Processes 149 709 717 Y scie scopus 001506776200001 2-s2.0-105007292064 Engineering, Manufacturing Engineering Article Homogeneous bonding Plastic-metal hybrids Intermediate interface Laser printing Pre-mixture